chassis parts manual

Publication Number: 2295 Date:April 2006 (01/11)

CHASSIS PARTS MANUAL

COVERING:ENVIRO 400 MODELS

XB15LBRAXB15LBRAXB45LBRAX345NBRAX345PBRAX345MBRAXB15MBRAXE15MBRAXD45LBRAXD45NBRAX346MBRAX346NBRAX346PBRAXB16LBRAXB16MBRAXE16MBRAXE16MBRE EURO 4, 4+ & 5-

Alexander Dennis Limited Alexander Dennis LimitedDennis Way, Guildford. 91 Glasgow RoadSurrey GU1 1AF Falkirk FK14JBTel: +44 (0) 1483 571271 Tel: +44 (0)1324 621672Fax: +44 (0) 1483 301696 Fax: +44 (0)1324 633120

This manual covers those Enviro 400 models listed on the front cover. It should be regarded as part of the product and retained with the vehicle.At the time of resale it should be passed on to any subsequent owner.

As the manual lists the specifications for several models, some of the items covered may not apply to your vehicle. If any doubt exists pleasedo not hesitate to contact your Alexander Dennis Parts Centre who will be pleased to offer technical assistance.

We would like to point out that non-Alexander Dennis parts have not been approved by Alexander Dennis and we cannot certify the suitabilitynor the safety of such parts. Alexander Dennis is not liable for any damage caused by the use of non-Alexander Dennis parts.

AMENDMENTS

Any amendments received should be incorporated into the text.

The amendment date appears at the top of the page.

This symbol, next to an item line, indicates that the item has been amended for the current issue of the page.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic,mechanical, photocopying, recording or otherwise without prior written permission of ALEXANDER DENNIS LIMITED .

3Enviro 400 - Parts Manual - Publication Number 2295 - January 2006

AFTER MARKET SUPPORT LINE

0845 358 9988FOR ALL ENQUIRIES

Including : Part Number Identification

Parts Ordering

Service Support

Warranty Support

Technical Support

FAX numbers : Parts Ordering 0845 358 9992

Technical Support 01483 451458

Warranty/Service 01483 301696

SERVICE DIRECTOR

BRIAN EVANS E-MAIL : [email protected]

MOBILE : 07881 825840

TECHNICAL SUPPORT MANAGER

REGIONAL SERVICE MANAGER STEVE HARDY

E-MAIL : [email protected]

MOBILE : 07788 717570

Service Assistance and Spare Parts Amended:

PARTS MANUAL

Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 4

ENVIRO 400

PARTS DIRECTOR

CUSTOMER MANAGEMENT ROB WILLIAMSE-MAIL : [email protected]

MOBILE : 07764 922274

LONDON & SOUTH EAST

REGIONAL PARTS MANAGER MARK BOWLEYE-MAIL : [email protected]

MOBILE : 07770 645212

SOUTH WEST & EU

REGIONAL PARTS MANAGER KEVIN YEARDLEYE-MAIL : [email protected]

MOBILE : 07979 705519

MIDLANDS

REGIONAL PARTS MANAGER GARY GLOVERE-MAIL : [email protected]

MOBILE : 07881 958463

NORTH

REGIONAL PARTS MANAGER LES RIVETTE-MAIL : [email protected]

MOBILE : 07843 357228

SCOTLAND & NI

REGIONAL PARTS MANAGER JIM WEBBE-MAIL : [email protected]

MOBILE : 07979 703605

Regional Parts Managers Amended:120111


LONDON, SURREY, HAMPSHIRE AND BERKSHIRE

JOHN CHAVES E-MAIL : [email protected]

MOBILE : 07760 220923

LONDON, KENT AND EAST & WEST SUSSEX

STEVE EDMONDS E-MAIL : [email protected]

MOBILE : 07831 704251

CENTRAL

REGIONAL SERVICE MANAGER GLEN WILKIE


MOBILE : 07736 615459

NORTH WEST & NORTHERN IRELAND & EIRE

REGIONAL SERVICE MANAGER BEN WAITE


MOBILE : 07901 510724

NORTH EAST & NORTHERN IRELAND & EIRE

REGIONAL SERVICE MANAGER JOHN BRADLEY


MOBILE : 07768 921192

SCOTLAND

REGIONAL SERVICE MANAGER DAVID ALLEN


MOBILE : 07770 733779

Regional Service Managers Amended:120111

PARTS MANUAL


ENVIRO 400

BRISTOL

BRISTOL SERVICE CENTRE: Folly Lane. St Philips. Bristol. BS2 0RH

TELEPHONE: 0117 955 0444 FAX : 0117 955 0666

OUT OF HOURS CONTACT : +44 (0) 7747 760 255

HARLOW

HARLOW SERVICE CENTRE: Unit B, Barrows Road, Pinnacles Industrial Estate.Harlow. Essex. CM15 5AT

TELEPHONE: 01279 770600 FAX : 01279 419744

COMMERCIAL MANAGER ALAN REYNOLDS

E-MAIL : alan [email protected]

MOBILE : 07799 762070

TRAINING

TRAINING MANAGER PAUL HOPWOODE-MAIL : [email protected]

MOBILE : 07831263246

Service Centres & Training Amended:

7Enviro 400 - Parts Manual - Publication Number 2295 - January 2006

Main Index Amended:120111

SERVICE ASSISTANCE AND SPARE PARTS

Section 1: GENERALHealth and Safety . . . . . . . . . . . . . . . . Page 1.2 - 4Environmental Warnings . . . . . . . . . . . Page 1.4Vehicle Identification . . . . . . . . . . . . . . Page 1.5Quick Reference Spares . . . . . . . . . . . Page 1.6 - 1.15Fastener identification . . . . . . . . . . . . . Page 1.16 - 21Miscellaneous . . . . . . . . . . . . . . . . . . . Page 1.22

Section 2: ENGINEAir Cleaner . . . . . . . . . . . . . . . . . . . . . . Page 2.2 - 3Cooling System . . . . . . . . . . . . . . . . . . Page 2.4 - 25Exhaust System . . . . . . . . . . . . . . . . . . Page 2.26 - 33Fuel System . . . . . . . . . . . . . . . . . . . . . Page 2.34 - 61Hydraulic System . . . . . . . . . . . . . . . . Page 2.62 - 71Engine & Mounting . . . . . . . . . . . . . . . Page 2.72 - 85Heater Pipework . . . . . . . . . . . . . . . . . Page 2.86 - 87Air Conditioning . . . . . . . . . . . . . . . . . Page 2.88 - 89

Section 3: TRANSMISSIONVoith Transmission . . . . . . . . . . . . . . . Page 3.2 - 3.3ZF Transmission . . . . . . . . . . . . . . . . . Page 3.4 - 3.5ZF Transmission Air Piping . . . . . . . . . Page 3.6 - 3.7Propeller Shaft . . . . . . . . . . . . . . . . . . . Page 3.8 - 3.9Rear Axle . . . . . . . . . . . . . . . . . . . . . . Page 3.10 - 23

Section 4: BRAKINGUsed on & up to Chassis No 5114 Braking System . . . . . . . . . . . . . . . . . . Page 4.2 - 5Pipe Fittings - Braking System . . . . . . . Page 4.6 - 9Used on & after Chassis No 5115 onwardsBraking System . . . . . . . . . . . . . . . . . . . Page 4.10 - 13Pipe Fittings - Braking System . . . . . . . Page 4.14 - 17Front Brake Chambers & Rear Brake Actuators . . . . . . . . . . . . . Page 4.18 - 19Footbrake Valve and Valve Assembly . Page 4.20 - 23Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . Page 4.24 - 25Handbrake Interlock . . . . . . . . . . . . . . . Page 4.26 - 27Brake Caliper & Spares . . . . . . . . . . . . Page 4.28 - 35Nylon Brake Tubing Sizes . . . . . . . . . . . Page 4.36

PARTS MANUAL

8

ENVIRO 400

Enviro 400 - Parts Manual - Publication Number 2295 - January 2006

Main Index Amended:090209

Section 5: ELECTRICAL SYSTEM AND INSTRUMENTATIONUsed on & up to Chassis No 5114 excluding 4625 & 4752

Instrument binnacle assembly . . . . . . Page 5.2 - 5Electrical Distribution Centre - FEDC . Page 5.6 - 7PCB board assembly - front . . . . . . . . Page 5.8 - 9Rear Electrical Distribution Centre REDC Page 5.10 - 11Cables . . . . . . . . . . . . . . . . . . . . . . Page 5.14 - 15Harnesses . . . . . . . . . . . . . . . . . . . . . . Page 5.16 - 17Miscellaneous . . . . . . . . . . . . . . . . . . . Page 5.18 - 19

BATTERY CARRIER AREABattery Carrier . . . . . . . . . . . . . . . . . . Page 5.20 - 23Battery Boost Socket . . . . . . . . . . . . . Page 5.23

Used on & after Chassis No 4625, 4752, 5115 onwardsElectrical System

Instrument binnacle assembly . . . . . . Page 5.26 - 27Front Electrical Distribution Centre - EDC Page 5.28 - 29PCB assembly - Front EDC . . . . . . . . . Page 5.30 - 31Rear Electrical Distribution Centre - EDC Page 5.32 - 33PCB assembly - Rear EDC . . . . . . . . . Page 5.34 - 35Cables . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.36Harnesses . . . . . . . . . . . . . . . . . . . . . . Page 5.37

Battery CarrierBattery Carrier Area . . . . . . . . . . . . . . . Page 5.38 - 39

Section 6: SUSPENSION, FRAME, WHEELSSuspension . . . . . . . . . . . . . . . . . . . . . Page 6.2 - 19Frame . . . . . . . . . . . . . . . . . . . . . . Page 6.20 - 23Cab Floor . . . . . . . . . . . . . . . . . . . . . . Page 6.24 - 25Wheels . . . . . . . . . . . . . . . . . . . . . . Page 6.26 - 27

Section 7: STEERING, FRONT AXLESteering . . . . . . . . . . . . . . . . . . . . . . Page 7.2 - 9Front Axle - DANA . . . . . . . . . . . . . . . . Page 7.10 - 19Front Axle - ZF . . . . . . . . . . . . . . . . . . . Page 7.20 - 23

ALPHABETICAL INDEX


Contents

General Amended:120111

Health and SafetyMoving the Vehicle . . . . . . . . . . . . . . . . Page 1.2Working on the Vehicle . . . . . . . . . . . . . Page 1.2Hazardous Materials . . . . . . . . . . . . . . . Page 1.3 - 4Environmental Warnings . . . . . . . . . . . . Page 1.4

Vehicle IdentificationVehicle Compliance Plate . . . . . . . . . . . Page 1.5

Quick Reference Spares . . . . . . . . . . . . . . . Page 1.6 - 15

Fastener identification . . . . . . . . . . . . . . . . Page 1.16 - 21Bolts and Screws . . . . . . . . . . . . . . . . . . Page 1.16 - 17Split Pins . . . . . . . . . . . . . . . . . . . . . . . . Page 1.17Nuts . . . . . . . . . . . . . . . . . . . . . . . . . Page 1.17Washers . . . . . . . . . . . . . . . . . . . . . . . . Page 1.18Self Tapping Screws . . . . . . . . . . . . . . . Page 1.18'P' Clips . . . . . . . . . . . . . . . . . . . . . . . . . Page 1.19Beam Clip . . . . . . . . . . . . . . . . . . . . . . Page 1.20Protective Sleeving . . . . . . . . . . . . . . . . Page 1.21Cable Ties . . . . . . . . . . . . . . . . . . . . . . . Page 1.21Hose Clips . . . . . . . . . . . . . . . . . . . . . . . Page 1.22Pipe Clamps . . . . . . . . . . . . . . . . . . . . . Page 1.23

LubricationLubrication . . . . . . . . . . . . . . . . . . . . . . Page 1.24 - 25

MiscellaneousAbbreviations . . . . . . . . . . . . . . . . . . . . Page 1.26

Section 1

PARTS MANUAL

Enviro 400 - Parts Manual - Publication Number 2295 - January 2006 1.2

ENVIRO 400

Moving the Vehicle

During movement of the vehicle chassis the hazards involved are thosenormally associated with all forms of powered transport.

Before driving the vehicle, operators should familiarise themselves with thevehicle operator’s handbook.

Working on the VehicleBefore commencing work on the vehicle, take note of all instructions relating tosafety and hazardous items.

The following potential hazards should be considered:

Stored EnergyCertain components and systems on the vehicle contain stored energy whichmust not be released in a non approved manner.

• Tyre air pressure.

• Braking system air pressure.

• Park brake spring compression.

Cooling System Pressure and TemperatureThe system will remain hot and under pressure after use. Allow to cool beforeattempting to remove the filler cap.

Chassis LiftingAdequate support required during jacking or lifting. Eye and head protectionshould be worn when working under the vehicle.

Diesel Injection PumpsSupply fuel to the engine at very high pressure, care must be taken whenworking on the injectors or injection pipes as fuel under high pressure canpenetrate the skin.

Braking SystemBrake drums or discs will remain at an extremely high temperature for aconsiderable time after use, caution must be exercised when handling suchitems to avoid burns.

Self Locking Nuts • When self locking nylon type nuts are removed, they should be

disgarded and new items used. THEY SHOULD NEVER BE RE-USED.

Health and Safety Amended:080708

�� Use Common Sense - If in Doubt Ask


Hazardous MaterialsCertain components on the vehicle contain, or can produce, material whichmust be handled cautiously. These materials are as follows:

Those which must not be taken internally or contact the eyes, skin, ormouth:

Battery acidDiluted sulphuric acid can cause skin burns, eye damage and internal damageif ingested. Vapour from the solution can also irritate the respiratory system andthe eyes.

Cooling system antifreezeBased on ethylene glycol, and has significant toxicity if ingested, but can alsobe absorbed through the skin. Causes mild eye and skin irritation. Hot fluid canalso scald.

FuelDiesel fuel is a mixture of hydrocarbons largely consisting of paraffinichydrocarbons, with blended constituents such as refined vacuum distillants andcatalytically cracked oil. Contact with the skin can cause irritation anddermatitis. Inhalation and ingestion are serious risks and can cause chemicalpneumonitis.

Hydraulic FluidsThese are generally made from polyalkylene glycol ethers and can cause mildirritation of the skin and eyes. The toxicity through ingestion is generallyregarded to be low order.

Friction Material DustMay consist of a high percentage of white asbestos bonded in a resin. Handlingand fitting lined brake shoes or clutch plates is not regarded as a health risk.The dust produced by worn linings is degraded by the brake or clutch is notbelieved to be hazardous. However it is prudent to avoid generating airbornedust concentration, therefore dust removal should be by the use of approvedvacuum cleaner or by the use of a damp cloth (for occasional exposure).

Insulation MaterialsMan made fibres which include glass, rock, slag and metal oxides. These maycause skin irritation. Inhalation of dust from the fibres should be kept below 1fibre/ml.

Mineral oil (Engine and Transmission)This type of oil contains small quantities of polycyclic aromatic hydrcarbons,which can cause irritation, dermatitis and oil acne if allowed persistent contactwith the skin. Toxicity through ingestion is of a low order, however this shouldbe avoided.

Exhaust EmissionsSubstances produced are carbon monoxide, hydrocarbons and oxides ofnitrogen. Can be highly toxic if inhaled in sufficient quantity. Emissions inenclosed spaces should be minimised unless adequate extraction facilities areavailable.

PERSONAL POINTS Remember to:Remove rings, watches before working on the vehicle, particularly necessarywhen working on the electrical system.Wear eye and head protection when working underneath the vehicle.Use barrier cream or wear gloves as necessary to protect hands.Keep loose clothing and long hair away from moving parts.

These instructions are for your own and others safety and are by no meanscomprehensive.

Each job and situation should be assessed for its Health, Safety andEnvironmental Risks as these will change and vary depending on the taskundertaken.



PARTS MANUAL


ENVIRO 400

Viton ‘O’ rings and seals (fluoro-elastomers)‘Viton’ material, used in the manufacture of oil seals and ‘O’ rings, produces ahighly corrosive acid (hydroflouric) when subjected to temperatures above315°C. The resulting contamination can have extreme consequences onhuman tissue since it is almost impossible to remove after contact.

The following procedure is recommended when it is necessary to inspect anyequipment that has been subjected to a high temperature i.e. fire.

1. Visually inspect for any gaskets or seals which have suffered from heat;they will appear black and sticky.

2. If this is affirmed:- Do not touch.

3. Make enquiries to ascertain material composition.

Any fluoro-elastomer (Viton, Flourel or Tecmoflon) should be considereddangerous but natural rubber and nitrile are non-hazardous.

4. If fluoro-elastomer seals have been used, then the affected area MUSTbe decontaminated before undertaking further work.

5. Disposable heavy duty gloves (neoprene) MUST be worn and theaffected area decontaminated by washing thoroughly with limewater(calcium hydroxide solution).

6. Any cloths, residue and gloves used MUST be safely discarded afteruse.

ENVIRONMENTAL WARNINGS

Those which may cause noxious fumes if allowed to burn:Coatings (Mebon chassis protection)Generally inert in the cured state, but should be removed from areas to bewelded.

Fuel (diesel)Not classified as flammable for most purposes.

Hydraulic FluidsThese do not present a fire or explosive hazard under normal circumstances.

Mineral oil (engine and transmission)These do not present a fire or explosive hazard under normal circumstances.

Rubber and synthetic alternatives (tyres, hoses, bushes, seals,insulation)Natural and synthetic rubbers are combustible and will produce unpleasant anddangerous fumes.


�� WARNING

Used engine oil, hydraulic fluids, transmission fluid, antifreeze, (and theircontainers) batteries and tyres can be a hazard to health and the environment.

Fluids and other substances (e.g. used oil) and surplus parts must bedisposed of in a safe and environmentally sound manner.

On no account must any of these items be placed in household refuse bins,or the fluids poured down drains.

Observe local regulations and laws on environmental protection and disposalof hazardous materials.

These should be disposed of using authorised waste disposal facilities.

Consult local authority for safe disposal facilities.

Burning of discarded items is NOT RECOMMENDED, except in anapproved incineration process where gaseous products are treatedby alkaline scrubbing.


Vehicle Identification Number Amended:


W.P.O.

VEHICLETYPE

ENGINETYPE

CABTYPE

53220

TRIDENT 2

CUMMINS ISBe4 250B

DENNIS ALEXANDER LIMITED

TA

SFD15LBRA5GXB3872V.I.N.

17800 18000

6300

11500

7500

11500

Kg

Kg

Kg

Kg

Kg

Kg

Kg

Kg

Kg

Kg

A

B

C

D

E

F

DESIGNWEIGHTS

PLATEDWEIGHTS

KEY TO VIN PLATE

SFD World Manufacturers Identity

1 Wheelbase

5 Engine

L Transmission

B Air ConditioningR Hand of DriveA Series / marK

5 (*) Build / Year

G Build Plant

X Model

B Frame Type

1234 Serial Number

A Type Approval Number

B Vehicle Identification Number

C Gross Weight

E Axle 1 Weight

F Axle 2 Weight

PARTS MANUAL


ENVIRO 400

Quick Reference Spares Amended:

1

76

432

LIFT L

EVER FULL

Y

TO UNLO

CK & R

ELEASE P

RESSURE

50KPA

11

8

129 10

5

50K

Pa

Quick Reference Spares Amended:120907

ITEM PART NO QTY DESCRIPTION REMARKS

AIR CLEANER1 651031-1 1 Element - Air cleaner - engine2 658566 1 Filter restriction indicator

AIR CONDITIONING3 7040801N01 1 Drive belt 4 7040800N01 1 Air conditioning compressor

COOLING SYSTEM5a 427381 1 Radiator insert5b 442973 1 Radiator Insert - aluminium

Supplied c/w rubber mountings and can be fitted to earlier pack 4419436 430554 1 Charge cooler7 435466 1 Fly Screen8 429792 1 Header tank assembly9 654109 1 Pressure cap

10 659659 1 Pressure cap - lever release (Option) OL1520-111 652489 1 Probe - coolant level

652490 1 Grommet - coolant level probe

12 659137 1 Mount - radiator


This section contains a list of service items, selected spares and control units to save time when identifyingthe more common service spares.This is designed to be an aid and not a comprehensive list.

PARTS MANUAL


ENVIRO 400


21

201917

1514

22 23 24 FUELFUEL/WATERFUEL

13

18




EXHAUST SYSTEM13 4931680 1 Silencer assembly - EGP14 660872-5 1 Flexible pipe15 660890 5 Mount - high temperature

FUEL SYSTEM16 658137 1 Filler cap - hinged

658137-1 1 Gasket - filler neck17 660828 1 Filter - Urea18 4936201-101 1 Nozzle - Injector EGP

4935801-101 1 Nut - EGP Injector660809-14 1 Ferrule - braided pipe660809-15 1 Nut - braided pipe

HYDRAULIC SYSTEM19 655644-1 2 Element - steering reservoir20 656730-1 1 Element - Hydraulic filter21 660344 1 Filler & breather unit c/w screw

ENGINE22 DP010206 1 Fuel filter - engine mounted - Primary23 659523-1 1 Fuel / water filter - frame mounted - secondary

659523-2 1 Sensor - water in fuel24 DP010205 1 Engine Oil Filter

PARTS MANUAL


ENVIRO 400


33

29

35

26 27

32

25

KNORR - BREMSE

VOITH

28

30 31

3634




ENGINE (continued)25 661096 1 Starter motor

26a 659717 1 Alternator AC172RA - 140A - Used on & upto Chassis No 422727a 3289001-101 1 Belt - alternator

432296 1 Pulley26b 661098 1 Alternator AC172RA - 155A - Used on & after Chassis No 422827b 4988883-101 1 Belt - alternator

3281533-101 1 Pulley

TRANSMISSION28a 660878-7 1 Oil filter kit - Voith Transmission28b 652638-1 1 Oil filter kit - ZF Transmission

29 652061-1 1 Pressure switch - Voith

PROPSHAFT30 659186 2 Joint kit

REAR AXLE31 658470-41 1 Brake pad set (axle set)32 660426-4 2 Seal - drive shaft

BRAKING SYSTEM33 658208-3 1 Replacement Cartridge - Air dryer

ELECTRICAL SYSTEM34 660879 1 Transmission electronic control unit - Voith

35a 660940 1 Transmission electronic control unit - ZF36a 659974 1 ABS ‘D’ electronic control unit36b 660811 1 ABS ‘E’ electronic control unit

662093 1 Harness - adaptor - ABS-D TO ABS-E (Needed if replacing ABS-D ECU) SL2315

PARTS MANUAL


ENVIRO 400


4645

41

37

44

CA

MU

43

3938

42

47 48

40

10

651598-




ELECTRICAL SYSTEM (continued)

37a 651598-2 A/R Add-A-Fuse - 3 Amp - Violet37b 651598-4 A/R Add-A-Fuse - 5 Amp - Tan37c 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown37d 651598-6 A/R Add-A-Fuse - 10 Amp - Red37e 651598-7 A/R Add-A-Fuse - 15 Amp - Blue37f 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow38a 656674 A/R Fuse - “maxi” - 20 Amp - Yellow38b 660060 A/R Fuse - “maxi” - 25 Amp - Grey38c 656548 A/R Fuse - “maxi” - 30 Amp - Green38d 660061 A/R Fuse - “maxi” - 35 Amp - Brown38e 657794 A/R Fuse - “maxi” - 40 Amp - Orange39 656334 2 Battery-12v40 659973 1 Control Unit - CAMU

659972 5 Control Unit - IOU41 661828 1 Screen Control Unit - black & white

AIR SUSPENSION42 655710-1 1 Line filter43 656298-1 2 Air spring diaphragm - front axle

656299-2 4 Air spring diaphragm - rear axle44 656606 1 Solenoid valve - 3-way

656607 1 Solenoid valve - single

SUSPENSION45 657610 4 Front damper c/w mounting

657611 4 Rear damper c/w mounting657696-3 A/R Retainer657610-1 A/R Rubber mounting c/w sleeve657696-4 A/R Lock nut

46 438257 1 Bush - link plate - Front suspension Replace all47a 434216 4 Bush half- Anti roll bar - Front suspension Replace all47b 434214 4 Bush half - Anti roll bar. - drive axle48 434947 4 Mounting rubber - Anti roll bar. - upper link - drive axle

PARTS MANUAL


ENVIRO 400


5150 52

53

57

565554

49




SUSPENSION49 658973 8 Mounting rubber - Anti roll bar. - ends - drive axle50 657505 1 Proximity switch

STEERING GEAR51a 658521-22 1 Socket assembly R/H 51b 658521-23 1 Socket assembly L/H 52 412555-8 1 Relay shaft53 611511 1 Universal joint assembly

FRONT AXLE54a 658470-41 1 Brake pad kit (axle set) - SB Caliper)54b 660364-7 1 Brake pad kit (axle set) - SN caliper)55a 658470-39 2 Brake Disc - Front - Dana 55b 661773-9 2 Brake Disc - Front - ZF56 657303-126 2 Brake Disc - Rear57 659334-8 1 Kit - wear indicator with cable (axle set)

PARTS MANUAL


ENVIRO 400

IntroductionAll attaching hardware are given a part number in a standard code which exactlyidentifies each item.

Bolts and Screws

Grade of Material

Blank . . . . . . . . . . . . . . . 8.8 metric or "S" imperial

10 . . . . . . . . . . . . . . . 10.9 metric

12 . . . . . . . . . . . . . . . 12.9 metric

R . . . . . . . . . . . . . . . R grade nut (imperial)R" grade nut is used with "V" grade bolt

T . . . . . . . . . . . . . . . T grade nut (imperial)"T" grade nut is used with "X" grade bolt

V . . . . . . . . . . . . . . . V grade bolt (imperial)

X . . . . . . . . . . . . . . . X grade (imperial)

Thread

BA . . . . . . . . . . . . . . . BABF . . . . . . . . . . . . . . . B.S.F.MC . . . . . . . . . . . . . . . Metric Coarse MF . . . . . . . . . . . . . . . Metric FineUC . . . . . . . . . . . . . . . Unified CoarseUF . . . . . . . . . . . . . . . Unified FineBC . . . . . . . . . . . . . . . B.S.W.

Type

B . . . . . . . . . . . . . . . BoltG . . . . . . . . . . . . . . . GrubscrewN . . . . . . . . . . . . . . . NutS . . . . . . . . . . . . . . . Screw

Tool

Blank . . . . . . . . . . . . . . . Spanner1 . . . . . . . . . . . . . . . Screw driver (conventional)2 . . . . . . . . . . . . . . . Pozidrive or Philips type screwdriver3 . . . . . . . . . . . . . . . Alan key (hexagonal socket head)4 . . . . . . . . . . . . . . . Coach type head

Head

Bolts and Screws1 . . . . . . . . . . . . . . . Hexagonal2 . . . . . . . . . . . . . . . Square3 . . . . . . . . . . . . . . . Flat csk4 . . . . . . . . . . . . . . . Raised csk5 . . . . . . . . . . . . . . . Round6 . . . . . . . . . . . . . . . Cheese or cap7 . . . . . . . . . . . . . . . Raised csk for instruments8 . . . . . . . . . . . . . . . Mushroom or cup9 . . . . . . . . . . . . . . . Pan

10 . . . . . . . . . . . . . . . Durlock

Grubscrews1 . . . . . . . . . . . . . . . Plain2 . . . . . . . . . . . . . . . Cup3 . . . . . . . . . . . . . . . W - point4 . . . . . . . . . . . . . . . Cone5 . . . . . . . . . . . . . . . Half dog6 . . . . . . . . . . . . . . . Full dog

Fastener Identification Amended:

Grade Thread Type Tool Head Diameter Length Finish

10 MC S 3 3 10 80 P

Diameter (two digits)BA sizes . . . . . . . . . gauge numberBSF, UNF, BSW . . . diameter in sixteenths of an inchMetric . . . . . . . . . . . diameter in millimetresBA, BSF, UNF, BSW length in eighths of an inchMetric . . . . . . . . . . . length in millimetres

Length (two or three digits)

BA, BSF, UNF, BSW length in eighths of an inchMetric . . . . . . . . . . . length in millimetres

Finish

C . . . . . . . . . . . . . . . Chrome plateP . . . . . . . . . . . . . . . Cadmium or zinc plate, sheradized or passivatedS . . . . . . . . . . . . . . . StainlessB . . . . . . . . . . . . . . . Black passivated

Split Pins

Diameter

One or two figures indicate diameter in sixty - fourths of an inch

LengthOne or two figures indicate length in sixteenths of and inch

MaterialBR . . . . . . . . . . . BrassST . . . . . . . . . . . Mild steel

Nuts

Thread

BA . . . . . . . . BABF . . . . . . . . B.S.F.MC . . . . . . . . Metric Coarse MF . . . . . . . . Metric FineUC . . . . . . . . Unified CoarseUF . . . . . . . . Unified FineBC . . . . . . . . B.S.W.

Type1 . . . . . . . . Full Plain2 . . . . . . . . Half plain (locknut)3 . . . . . . . . Castle4 . . . . . . . . Slotted5 . . . . . . . . Full, self locking6 . . . . . . . . Thin, self locking7 . . . . . . . . Full Nyloc or Simmonds8 . . . . . . . . Thin Nyloc or Simmonds9 . . . . . . . . Square

Size (two digits)Thread diameterMetric - millimetresBSF, UNF, BSW - sixteenths of an inch

FinishC . . . . . . . . Chrome plateP . . . . . . . . Cadmium or zinc plate, sheradized or passivatedS . . . . . . . . StainlessB . . . . . . . . Black passivated


Thread Nut Type Size Finish

BC N 5 20 P

Split Pin Diameter Length Material

SP 6 12 ST


PARTS MANUAL


ENVIRO 400

Washers

Measuring SystemWB . . . . . . . . BA sizesWG . . . . . . . . Woodscrew gauge sizesWL . . . . . . . . Inch sizeWM . . . . . . . . Metric sizes

TypeA . . . . . . . . Plain, flatB . . . . . . . . Spherical or BellevilleC . . . . . . . . Single coil springD . . . . . . . . Double coil springE . . . . . . . . External starF . . . . . . . . Countersunk internal starG . . . . . . . . Internal starH . . . . . . . . Internal and external starJ . . . . . . . . Cup

SizeOne or two figures give the internal diameter in:

Screw gauge sizeBA numberSixteenths of an inchMillimetres

MaterialA . . . . . . . . AluminiumB . . . . . . . . BrassC . . . . . . . . CopperS . . . . . . . . Steel

FinishC . . . . . . . . Chrome plateN . . . . . . . . Nickel plateO . . . . . . . . NaturalP . . . . . . . . Cadmium or zinc plate, sheradized or passivatedB . . . . . . . . Brassed

Self-Tapping Screws

ToolBlank . . . . . . . . . . . Spanner

1 . . . . . . . . . . . Screw driver (conventional)2 . . . . . . . . . . . Pozidrive or Philips type screwdriver3 . . . . . . . . . . . Allen key (hexagonal socket head)4 . . . . . . . . . . . NA5 . . . . . . . . . . . Plain, i.e. hammer drive

Head1 . . . . . . . . . . . Hexagonal2 . . . . . . . . . . . Square3 . . . . . . . . . . . Flat C'sk4 . . . . . . . . . . . Raised cheese head (fillister)5 . . . . . . . . . . . Round6 . . . . . . . . . . . Cheese or cup7 . . . . . . . . . . . Raised C'sk. (instrument)8 . . . . . . . . . . . Mushroom or cup9 . . . . . . . . . . . Pan

SizeOne or two figures give the diameter in screw gauge number.

LengthOne or two figures give the length in eighths of an inch

FinishC . . . . . . . . . . . Chrome plateN . . . . . . . . . . . Nickel plateO . . . . . . . . . . . NaturalP . . . . . . . . . . . Cadmium or zinc plate, sheradized or passivatedB . . . . . . . . . . . Brassed


Measuring System Type Size Material Finish

WM C 10 S PSelf Tap Tool Head Screw Length Finish

ST 1 3 08 5 P


'P' Clips 'P' Clips - High Temperature

Fastener Identification Amended:120111

Inside dia Part No. Inside Part No.inches (mm) diameter (mm)

4 611673-1 21 610029-5

5 611673-2 0.906” (23) 660217-6*

6 611673-3 0.953” (24) 660217-7*

7 611673-4 1.063” (27) 660217-8*

8 611673-5 31 660217-9*

9 611673-6 1.234” (38) 660217-10*

10 611673-7 39 610029-11

11 611673-8 1 3⁄4” (45) 660217-12*

12 611673-9 51 610029-13

1/2 ” (13) 660217-1* 2 1⁄4” (57) 660217-14*

- 14 610029-2 70 610029-15

5/8” (17) 660217-3* 1” (25) 660217-20*

3/4” (19) 660217-4* 2.5” 442489*

Inside dia Part No. Inside Part No.inches (mm) diameter (mm)

4 611673-1 21 610029-5

5 611673-2 0.906” (23) 660217-6*

6 611673-3 0.953” (24) 660217-7*

7 611673-4 1.063” (27) 660217-8*

8 611673-5 31 660217-9*

9 611673-6 1.234” (38) 660217-10*

10 611673-7 39 610029-11

11 611673-8 1 3⁄4” (45) 660217-12*

12 611673-9 51 610029-13

1/2 ” (13) 660217-1* 2 1⁄4” (57) 660217-14*

- 14 610029-2 70 610029-15

5/8” (17) 660217-3* 1” (25) 660217-20*

3/4” (19) 660217-4* 2.5” 442489*

PARTS MANUAL


ENVIRO 400

P Clips - High Temperature

Beam / Frame Clip - Cables and Pipes


A -Frame B - Clip Part No.Thickness (mm) Diameter (mm)

8 - 12 6-7 656880-1

A

B

A -Frame B - hole Part No.Thickness (mm) Diameter (mm)

5 - 10 6.5 611075

AB

A -Frame B - hole Part No.Thickness (mm) Diameter (mm)

4 6.5 656737

A

B

Part No: Diameter Diameter (mm) (mm)

657677-1 10 8.4

657677-2 6 6.4


Protective Sleeving Cable Ties


Inside diameter

Closed (mm) Max: open (mm) Part No.

6.7 25.4 610561/1

9.3 44.5 610561/2

13.2 63.5 610561/3

19.9 127.0 610561/4

26.1 178.0 610561/5

14.0 75.0 610561/6

Length (mm)

Length (mm) Part No.

115mm 607008

130 - 133mm wide 653608

190 - extra wide 610808

266mm 607007

Spacer

Diameter (mm) Part No.

25mm 656844

PARTS MANUAL


ENVIRO 400

Hose Clips - constant torque

Constant Torque


Dia Min Dia Max Part No. Torque(mm) (mm) Standard Setting

12 22 661990-3 3.0 +0.5 Nm

16 27 661990-4 5.0 +0.5 Nm

20 32 661990-5 5.0 +0.5 Nm

23 35 661990-6 5.0 +0.5 Nm

25 40 661990-7 5.0 +0.5 Nm

30 45 661990-8 5.0 +0.5 Nm

35 50 661990-9 5.0 +0.5 Nm

40 60 661990-10 5.0 +0.5 Nm

50 70 661990-11 5.0 +0.5 Nm

60 80 661990-12 5.0 +0.5 Nm

70 90 661990-13 5.0 +0.5 Nm

80 100 661990-14 5.0 +0.5 Nm

90 110 661990-15 5.0 +0.5 Nm

100 120 661990-16 5.0 +0.5 Nm


Pipe clamps


A - Centres B-hole Part No.(mm) Diameter (mm)

36 25 658591-1

Cover plate for above - 658592-1

B B

A

A

B

d D

6.5

Part No. a b h d D Cover PlatePart No.

653488-1 38 70 30.5 16 16 653489-1

653488-2 38 70 30.5 19 19 653489-1

653488-3 38 70 30.5 19 20 653489-1

653488-4 30 54 23.5 16 16 653489-2

Part No. a b h d D

653487-1 19 40 30.5 16 16

653487-2 19 40 30.5 19 19

653487-3 19 40 30.5 19 20

653487-4 15 33 23.5 16 12

ab

7

Ø6.5Ød

14.5

h

PARTS MANUAL


ENVIRO 400

Lubricants and Fluids Amended:

Unit No:FZ1510

413

6

5

2

6 8 9 7

7


Unit No:FZ1510

Lubricants and Fluids Amended:080708

* When using products other than those supplied by Texaco/Fuchs, consult your supplier to confirm compatibility.

** This Valvoline Antifreeze, to Cummins 14603, must be used for vehicles fitted with an Aluminium Radiator Insert .

Ref. Vehicle Part Capacity in General RecommendedNo. Component Number litres (approx.) Specification Brands

1 Engine Cummins ISBe4 659047-1 20.5 To a minimum of europeanclassification ACEA E5 Fuchs Titan HPE15W40. Cummins 20072

2a Transmission - Voith 657507-1 28 * Dexron III Texamatic 7045*Oil change 26

2b Transmission - ZF 657507-1 30 * Dexron III Texamatic 7045*Oil change 15

3 Drive axle 650803 19.0 API - GL5 Texaco Geartex

Oil change 18.5 85W/140 EPB 140

4 Cooling System 660252-1 55 To Cummins 14603 Valvoline HD Extended Life RTU

approx Prediluted mix - DO NOT ADD WATER

5 Steering Reservoir 657507-1 6.0 * Dexron III Texamatic 7045*Fan Drive Reservoir 657507-1 7.0 * Dexron III Texamatic 7045*

6 Rear Axle Hubs - 0.13 - 0.15kg/hub Fuchs Renolit LX PEP 2 Fuchs Renolit LX PEP 2

7 Grease Points: 603472 A/R Multi purpose Texaco Multifak EP2Steering shaftPropshaft grease pointsBattery carrier slide

8 Fuel Tank - 275 Ultra Low Sulphur Diesel City Diesel

9 Urea Tank 660683 17 Urea reagent AdBlue® www.air1.info

PARTS MANUAL


ENVIRO 400

Abbreviations used in this manualABS Anti-Lock Brake System

A/R As required

BSP British Standard Pipe

FEDC Front Electrical Distribution Centre

JIC Joint Industries Council

LH Left Hand

MM Millimetre

NPT National Pipe Thread

NPTF National Pipe Thread Fine

REDC Rear Electrical Distribution Centre

RH Right Hand

SAE Society of Automotive Engineers

Miscellaneous Amended:


Contents

Engine Amended:070111

Air CleanerAir Cleaner Assembly . . . . . . . . . . . . . . . . Page 2.2 - 3

Cooling SystemCooling System - Voith Transmission . . . . Page 2.4 - 9Cooling System - ZF Transmission . . . . . . Page 2.10 - 15Cooling Pack Assembly . . . . . . . . . . . . . . Page 2.16 - 19Intercooler Assembly . . . . . . . . . . . . . . . . Page 2.20 - 21Header tank Assemblies . . . . . . . . . . . . . . Page 2.22 - 25

Exhaust SystemExhaust Gas Processor System . . . . . . . . Page 2.26 - 29Exhaust Gas Processor System Insulation Page 2.30 - 31Exhaust Gas Processor System Pipework Page 2.32 - 33

Fuel SystemUrea Tank - stainless steel . . . . . . . . . . . . Page 2.34 - 35Urea Tank - plastic . . . . . . . . . . . . . . . . . . Page 2.36 - 37Urea Tank - Identic . . . . . . . . . . . . . . . . . . Page 2.40 - 41Fuel Tank Assembly - Staircase . . . . . . . . Page 2.40 - 41Fuel Tank Assembly - Staircase - Identic . . Page 2.42 - 43Fuel Tank Assembly - Staircase - Posilock Page 2.44 - 45Fuel Tank Assembly - Wheel arch . . . . . . . Page 2.46 - 47Fuel Tank Assembly . . . . . . . . . . . . . . . . .

- Wheel arch - Identic Remote . . . . . . . . . Page 2.48 - 49

Used on & up to Chassis No 4191Fuel System Pipework - Staircase . . . . . . . Page 2.50 - 53Fuel System Pipework - Wheel arch . . . . . Page 2.54 - 57

Used on & up after Chassis No 4192Fuel System Pipework -

. . . . . . . .Wheelarch & Understair Page 2.58 - 59Fuel System Pipework - Engine Fuel Filter Page 2.60 - 61

Hydraulic SystemHydraulic System . . . . . . . . . . . . . . . . . . . Page 2.62 - 67Steering Reservoir Assembly . . . . . . . . . . Page 2.68 - 69Hydraulic Fan Reservoir Assembly . . . . . Page 2.70 - 71

Engine & MountingEngine and Mounting - Voith . . . . . . . . . . . Page 2.72 - 75Engine and Mounting - ZF . . . . . . . . . . . . Page 2.76 - 79Engine oil filler . . . . . . . . . . . . . . . . . . . . . Page 2.80 - 81Engine Service Sundries . . . . . . . . . . . . . . Page 2.82 - 83Alternator Mounting . . . . . . . . . . . . . . . . . Page 2.84 - 85

Heater pipeworkHeater Pipework . . . . . . . . . . . . . . . . . . . . Page 2.86 - 2.87

Air ConditioningAir Conditioning Compressor . . . . . . . . . . Page 2.88 - 2.89

Section 2

PARTS MANUAL


ENVIRO 400

Air Cleaner Amended:200112

Unit No: AC1511A

2

43

5

22

21

7

8

10

9

12

13

14

15

17

6

1

19

20

18

AR1511A

16


Unit No: AC1511A

Air Cleaner Amended:200112


1 651031 1 Air Cleaner2 651031-1 1 Element Assembly3 650551-3 1 Nut & gasket assembly4 651031-3 1 Cover assembly5 651031-2 1 Body assembly6 651032 1 Mounting band - air cleaner

MCS 110 20P 4 SetscrewMCN 510P 4 Nut

7 611005-9 2 Clip8 651058 1 Hump hose9 611005-2 2 Clip

10 440751 1 Air intake pipe11 611005-2 2 Clip12 611605 1 Elbow-reducing13 611005-2 1 Clip14 440752 1 Air intake pipe - short15 611005-6 2 Clip16 658566 1 Restriction indicator17 660718 1 Elbow - air outlet

611005-6 2 Clip - pipe to turbo18 434249-1 1 Elbow - inlet pipe

656818-7 2 Clip19 441223 1 Pipe - inlet pipe to compressor 20 434255 1 Elbow - compressor inlet

656818-7 2 Clip21 611007-5 1 Dust valve22 651034-4 1 Clip - dust valve

417594 1 Label - air cleaner

PARTS MANUAL


ENVIRO 400

Cooling System - Voith Transmission Amended:120907

Unit No: R1516A&R1517A

REAR

FRONT

9

2

6

7

19 42

4529

4

3

5

17

1

10

13

37

32

22

26

14

33

28

34

23

25

38

30

8

36

21

24

AR7935V-E400

46

18

12 11

15

35

27

40

20

31

44

4347

16

41

39





1 429792 1 Header tank assembly (See Separate List)2a 437722 1 Hose - tank fill AL1538-12b 435201-6 1 Hose - tank fill - (Non Enviro 400 bodies) AL1538-3

656818-10 2 Clip3a 440909 1 Filler neck3b 442382 1 Filler neck - Coolant level Check Option OL1541-14 434248-37 1 Hose - breather - tank to neck

656818-1 2 Clip5a 654109 1 Pressure cap5b 659659 1 Pressure cap - lever release (Option - replaces item 5a) OL1520-16 654242 1.75m Hose - drain7 434238-1 1 Hose - upper - sight gauge

656818-1 1 Clip - filler neck656818-2 1 Clip - sight gauge

8 425557 1 Sight gauge assembly430896 1 Front plate - sight glassMCS 1903 16P 4 Screw424128 1 Glass tube657359 2 Grommet436304 1 Bracket - sight glassMCN 103P 2 Nut

9 434238-1 1 Hose - lower - sight gauge)656818-2 1 Clip - sight gauge656818-1 1 Clip - header tank

10 434248-10 1 Hose elbow - tank to bleed pipe656818-2 2 Clip - pipe

11 409853 1 “Y” Bleed pipe12 434248-11 1 Hose - “Y” to bleed pipe

656818-2 2 Clip

PARTS MANUAL


ENVIRO 400



REAR

FRONT

9

2

6

7

19 42

4529

4

3

5

17

1

10

13

37

32

22

26

14

33

28

34

23

25

38

30

8

36

21

24

AR7935V-E400

46

18

12 11

15

35

27

40

20

31

44

4347

16

41

39





13 441227 1 Pipe assembly - bleed14 435198 1 Elbow - radiator

656818-1 1 Clip - pipe656818-2 1 Clip - radiator

15 434248-5 1 Hose assembly - “Y” pipe to elbow656818-2 2 Clip

16 659329-1 1 Elbow - bleed17 434248-22 1 Hose- engine

656818-1 2 Clip18 434776 1 Hose elbow - engine to pipe

656818-10 2 Clip19 440870 1 Pipe - elbow to convolute

403863 2 Bracket - “L” - pipe support20 434263 1 Hose convolute - pipe to pipe

656818-10 2 Clip402421 Bracket strip - P clip

21 440871 1 Pipe - hose to elbow22 434378 1 Hose elbow - 135°- pipe to elbow23 425498 1 Pipe assembly - hose to elbow24 5349-2 1 Plug (also see item 48)

603677 1 Bonded seal25 434375-2 1 Hose elbow - radiator inlet

656818-10 2 Clip26 435199 1 Hose “S” - radiator - Voith

656818-10 2 Clip27 441226 1 Pipe - transmission / radiator / bypass

435139 1 Bracket - pipe support - off transmission28 5349-2 1 Plug (also see item 48)

603677 1 Bonded seal

PARTS MANUAL


ENVIRO 400



REAR

FRONT

9

2

6

7

19 42

4529

4

3

5

17

1

10

13

37

32

22

26

14

33

28

34

23

25

38

30

8

36

21

24

AR7935V-E400

46

18

12 11

15

35

27

40

20

31

44

4347

16

41

39





29 694266 1 Elbow - bypass656818-4 2 Clip

30 441225 1 Pipe - bypass 444775 2 Bracket - pipe support - bellhousing

31 434252-4 1 Hose elbow - connecting - bleed pipes656818-4 2 Clip

32 439876 1 Pipe - bypass - to engine (See page 2.15, item 32 for details of elbow)33 434375-1 1 Hose elbow - transmission cooler - inlet

656818-10 2 Clip34 434246-1 1 Hose - transmission cooler - outlet

656818-10 2 Clip35 440873 1 Pipe assembly - transmission cooler to engine 36 439643 1 Hose elbow - engine inlet

656818-10 2 Clip - pipe to elbow37 434244 1 Hose - fill pipe

656818-9 2 Clip 38 440874 1 Pipe - make up39 434260 1 Hose - reducing elbow - tank outlet

656818-9 2 Clip40 658650 1 Valve - heater supply41 429610 1 Pipe - heater return42 440329 1 “F” Pipe assembly

440977 2 Connector - “F” pipe Torque 55 Nm43 434249-2 1 Hose elbow - “F” pipe44 441165 1 Pipe - heater feed (For further details see saloon heater pipework)45 658650 1 Valve - heater supply46 441166 1 Pipe - heater feed47 660159 1 Valve - coolant test point (Option) OL1524-1&2

652542 1 Reducer - -engine block48 658455-6 1 Drain Valve (Option - replaces items 24 & 28) OL1534-1

PARTS MANUAL


ENVIRO 400

Cooling System - ZF Transmission Amended:030910

Unit No: R1516B&R1517B&D

REAR

FRONT

16

39

GEARBOX COOLER

22

22

9

2

6

7

19 40

38

29

4

3

5

17

1

10

13

ENGINE

HEATERRETURN

SIGHTGAUGE

COOLANT HEADER TANK

HEATERSUPPLY

RA

DIATO

R

35

32

22

26

14

33

28

23

25

36

30

8

34

21

24

AR7936ZF-E400

44

18

12 11

15

33

27

38

20

31

43

4245

39

414146





1 429792 1 Header tank assembly (See Separate List)2a 437722 1 Hose - tank fill AL1538-12b 435201-6 1 Hose - tank fill - (Non Enviro 400 bodies) AL1538-3

656818-10 2 Clip3 440909 1 Filler neck4 434248-37 1 Hose - breather - tank to neck

656818-1 2 Clip5a 654109 1 Pressure cap5b 659659 1 Pressure cap - lever release (Option - replaces item 5a) OL1520-16 654242 1 Hose - drain7 434238-1 1 Hose - upper - sight gauge

656818-1 1 Clip - filler neck656818-2 1 Clip - sight gauge

8 425557 1 Sight gauge assembly430896 1 Front plate - sight glassMCS 1903 16P 4 Screw424128 1 Glass tube657359 2 Grommet436304 1 Bracket - sight glassMCN 103P 2 Nut

9 434238-1 1 Hose - lower - sight gauge)656818-2 1 Clip - sight gauge656818-1 1 Clip - header tank

10 434248-10 1 Hose elbow - tank to bleed pipe656818-2 2 Clip - pipe

11 409853 1 “Y” Bleed pipe12 434248-11 1 Hose - “Y” to bleed pipe

656818-2 2 Clip 13 441227 1 Pipe assembly - radiator bleed

PARTS MANUAL


ENVIRO 400



REAR

FRONT

16

39

GEARBOX COOLER

22

22

9

2

6

7

19 40

38

29

4

3

5

17

1

10

13

ENGINE

HEATERRETURN

SIGHTGAUGE

COOLANT HEADER TANK

HEATERSUPPLY

RA

DIATO

R

35

32

22

26

14

33

28

23

25

36

30

8

34

21

24

AR7936ZF-E400

44

18

12 11

15

33

27

38

20

31

43

4245

39

414146





14 435198 1 Elbow - radiator656818-1 1 Clip - pipe656818-2 1 Clip - radiator

15 434248-5 1 Hose assembly - “Y” pipe to elbow656818-2 2 Clip

16 659329-1 1 Elbow - bleed17 434248-22 1 Hose- engine

656818-2 2 Clip18 434776 1 Hose elbow - engine to pipe

656818-10 2 Clip 19 440870 1 Pipe - elbow to convolute

403863 2 Bracket - “L” - pipe support400463-8 2 Spacer

20 434263 1 Hose - straight - pipe to pipe656818-10 2 Clip402421 Bracket strip - P clip

21 440871 1 Pipe - hose to elbow22 434378 3 Hose - 45° elbow

656818-10 6 Clip23 425498 1 Pipe assembly - hose to elbow

401825 1 Bracket - pipe support (off fan cowl)24 5349-2 1 Plug (also see item 48)

603677 1 Bonded seal25 434375-2 1 Hose elbow - radiator inlet

656818-10 2 Clip26 434375-2 1 Hose elbow - radiator - Voith

656818-10 2 Clip27 441449 1 Pipe - transmission / radiator / bypass28 5349-2 1 Plug

603677 1 Bonded seal

PARTS MANUAL


ENVIRO 400



REAR

FRONT

16

39

GEARBOX COOLER

22

22

9

2

6

7

19 40

38

29

4

3

5

17

1

10

13

ENGINE

HEATERRETURN

SIGHTGAUGE

COOLANT HEADER TANK

HEATERSUPPLY

RA

DIATO

R

35

32

22

26

14

33

28

23

25

36

30

8

34

21

24

AR7936ZF-E400

44

18

12 11

15

33

27

38

20

31

43

4245

39

414146





29 444316 1 Elbow - bypass656818-4 2 Clip

30 441451 1 Pipe - bypass 444775 1 Bracket - bypass pipe (off transmission housing)660217-3 1 Clip - high temperature

31 434252-4 1 Hose -connecting - bleed pipes656818-4 2 Clip

32 439876 1 Pipe - bypass - to engine 3287186-101 1 Hose elbow3287185-101 1 Connector - engine block

33 441450 1 Pipe assembly - transmission cooler to engine 440774 1 Bracket - pipe support - downpipe to bellhousing

34 439643 1 Hose elbow - engine inlet656818-10 2 Clip - pipe to elbow

35 434244 1 Hose - fill pipe656818-9 2 Clip

36 440874 1 Pipe - make up441448 1 Plate - mounting - bypass mounting

37 434260 1 Hose - reducing elbow - tank outlet656818-9 2 Clip

38 658650 1 Valve - heater supply39 429610 1 Pipe - heater return40 440329 1 “F” Pipe assembly41 440977 2 Connector - “F” pipe42 434249-2 1 Hose elbow - “F” pipe43 441165 1 Pipe - heater feed44 441166 1 Pipe - heater feed45 660159 1 Valve - coolant test point (Option) OL1524-1

652542 1 Reducer - -engine block46 658455-6 1 Drain Valve (Option - replaces items 24 & 28) OL1534-147 660159 1 Coolant test point (use Volvo Service Tool - 9996049) OL1524-4

652542 1 Reducer652782 1 Elbow - 45 °

PARTS MANUAL


ENVIRO 400

Cooling Pack Assembly Amended:120111

Unit No: R1516A&B. R1517A,B&D

7

9

10

11

8

2

5

18

19

1

23

25

26

440690/441943

16/17

21

20

24

1415

13

1514

12

24

22

3a

3b

27





Used on and up to Chassis No 4363 including 4369 to 4374, 4387 to 4398 & 4402 to 4429. R1516A&B

441943 1 Cooling pack assembly (supercedes 440690)Used on and after Chassis No 4364 to 4368, 4375 to 4386, 4399 to4401, 44300 onwards. R1517A&C

442972 1 Cooling pack assembly - aluminium radiator

1a 427381 1 Radiator Insert1b 442973 1 Radiator Insert - aluminium Supplied c/w rubber mountings Can be fitted to earlier pack 4419432 435179-2 1 Fan cowl

MCS 106 16P 17 Setscrew - cowlWMA 6SP 17 Washer - springWMC 6SP 17 Washer - plain

3b 661142 1 Fan Blade - plastic (Used on Chassis No 4146 & after 4148 onwards)406935 1 Hub - plastic fan blade

3b 659981 1 Fan Blade - metal (Used up to Chassis No 4145 & 4147) 4 435179-4 1 Fan motor/carrier bracket - “top hat”

MCB 108 30P 4 Bolt - carrier to cowl652361 4 Washer - plainWMC 12SP 4 Washer - springMCN 508P 4 Nut

5 435179-3 2 Fan carrier arm6 661124 1 Fan motor (660051)

658086-1 1 Seal kitMCB 108 40P 4 BoltMCN 508P 4 Nut

7 659137 2 Flexible mounting - radiatorMCS 108 20P 4 Setscrew - mountingMCN 508P 4 Nut - mounting

NOTE : Valvoline Antifreeze, to Cummins 14603, must be used forvehicles fitted with an Aluminium Radiator Insert .

PARTS MANUAL


ENVIRO 400



7

9

10

11

8

2

5

18

19

1

23

25

26

440690/441943

16/17

21

20

24

1415

13

1514

12

24

22

3a

3b

27





8 190036 2 Washer - rebound 57 o/d9 409042 2 Washer clamp 30 o/d

10 MCB 112 85P 2 Bolt - mounting- radiator11 MCN 512P 2 Nut - mounting- radiator12 419390 1 Stud - straight - radiator mounting13 MCN 510P 4 Nut- self locking14 211401 8 Backing washer15 211402 4 Mounting rubber16 MCN 110P 8 Nut - plain17 MCN 210P 8 Nut - plain - half18 440690-1 1 Oil cooler

MCS 108 20P 2 SetscrewWMC 8SP 2 Spring washer

19 435466 1 Flyscreen425472-13 3 Retainer425472-14 3 Clip425472-15 3 Stud660157-4 1 Seal - rubber - flyscreen - lower660157-3 1 Seal - rubber - flyscreen - RH660157-9 1 Seal - rubber - flyscreen - LH

20 430554 1 Charge cooler Insert21 440690-5 1 Radiator frame22 659386 1 Hose adaptor - radiator top tank23 428035-4 1 Recirculating shield - RH - oil cooler24 428035-5 1 Recirculating shield - LH25 428035-6 1 Recirculating shield - top26 425472-10 1 Frame - bottom rail27 448050 1 Lower sealing plate

RADIATOR FOAM FILTER AL1550-1661333 1 Radiator filter kit661333-1 1 Filter - foam

PARTS MANUAL


ENVIRO 400

Intercooler Assembly Amended:120907

Unit No: R1516B&C. R1517A,B&D

3

37

11

6

3

2

3 5

3

11

R1516-E400

12

12

3

9

10

8

4

1


Unit No: R1516B&C. R1517A,B&D

Intercooler Assembly Amended:120907


1 611005-15 1 Clip tee bolt - turbo2 415733 1 Elbow - engine outlet3 611005-3 6 Clip - tee bolt4 441236 1 Pipe assembly - engine to intercooler5 415733 1 Hose 45° - intercooler to pipe6 430554 1 Charge cooler Insert7 413894 1 Hose - convolute8 441237 1 Pipe assembly - intercooler to turbocharger9 422764 1 Hose reducer - pipe to inlet manifold

10 611005-29 1 Clip - tee bolt11 656160-17 2 U clamp - pipe to engine frame12 426681 2 Bracket - U clamp

PARTS MANUAL


ENVIRO 400

Header Tank Assembly Amended:130111

Unit No: R1516B&C. R1517A,B&D - 429792,444689,OL1541-1 & OL1541-2

429792/444689-E400

1

54

3

3

6

5

4

2

7

8

COOLANT

OK TOP UP

PUSH TO CHECK

11

9

12


Unit No: R1516B&C. R1517A,B&D - 429792,444689,OL1541-1 & OL1541-2

Header Tank Assembly Amended:110111


1a 429792 1 Header tank assembly R1516B&C. R1517A&B2 428069-1 1 Insert - header tank (SL2125 - S/S replacement)3 428071-1 2 Insert - header tank 4 652489 1 Probe - coolant level5 652490 1 Grommet - coolant level probe6 658286-1 1 Insert - header tank 7 432308 2 Strap assembly - header tank 8 656768 2 Rubber strip - self adhesive - header tank brackets 0.5m

1b 444689 1 Header tank assembly - no probe R1517D443566 1 header tank and inserts

2 428069-1 2 Insert - header tank 3 428071-1 1 Insert - header tank 6 658286-1 1 Insert - header tank 9 660911 3 Plug

COOLANT LEVEL CHECK - WPO53424 OL1541-11c 442377 1 Header tank assembly - replaces 429792

442382 1 Filler neck (Replaces 440909 - no sight glass)442363 1 Kit - coolant check:

11 661230 1 Module - push button - coolant check442361 1 Harness - coolant check

COOLANT LEVEL CHECK - WPO53770 & WPO53789 OL1541-21d 442377 1 Header tank assembly - replaces 429792

442382 1 Filler neck (Replaces 440909 - no sight glass)11 661843 1 Module - push button - coolant check

446179 1 Harness - link - top up12 661850 1 Switch - coolant level

PARTS MANUAL


ENVIRO 400

Header Tank Assembly - Stainless Steel Amended:180310

Unit No: R1517D - 447030

447101-SS-HK

3

3

2

10

6a

4

7

9

8

5

6b


Unit No: R1521A - 447030

Header Tank Assembly - Stainless Steel Amended:130111


Used on and after Chassis No 5419 not including 5334 & 5378447030 1 Header Tank Assembly - stainless steel

1 447031 1 Header tank2 447061 1 Insert assembly - filler / breather 95mm3 441814 2 Insert assembly - vent tube 260mm4 659329-2 1 Elbow - header tank5 606078-34 2 Plug6a 660864 1 Sensor - coolant level7 432492 2 Strap assembly - header tank 8 MCN 506P 2 Nut9 WMA 6SP 2 Washer - plain10 656768 0.5m Rubber strip - self adhesive - header tank brackets

SL2297 1 Conversion kit - plastic to stainless - 1st Gen with sight glassIncludes items 2,3,5

447269 1 Header Tank Assembly - stainless steel652370-2 2 Probe - coolant level5349-2 1 Plug603677 1 Seal - dowtySL2298 1 Conversion kit - plastic to stainless - 1st Gen with level check

Includes items 2,3,5447269 1 Header Tank Assembly - stainless steel652370-2 3 Probe - coolant level

SL2299 1 Conversion kit - plastic to stainless - 2nd Gen with sight glassIncludes items 2,3,4,5 (Sensor 660864 to be removed from original)

447031 1 Header Tank Assembly - stainless steel

SL2300 1 Conversion kit - plastic to stainless - 2nd Gen with level checkIncludes items 2,3,5 (Sensor 660864 to be removed from original)

447031 1 Header Tank Assembly - stainless steel

PARTS MANUAL


ENVIRO 400

EGP - Exhaust Gas Processor System Amended:080311

Unit No: EGP1510A,B,C,D,H&J

660872/661131/661262 EGP

FROM TURBO

3

5

16

17

13

4

3

6

7

8

9

10a

11

12

13

14

15

19

20

2526

2

1

22

23

13

21

1324

SOFT LAGGING HARD LAGGING

EURO 4+EURO 5-

10b

18


Unit No: EGP1510A,B,C,D,H&J



660872 1 EGP Kit - Euro 4 - jacket lagging (BEIGE engine) EGP1510A&B

661131 1 EGP kit - Euro 4+ - hard lagging (RED engine) EGP1510C

661262 1 EGP kit - Euro 5- hard lagging (RED engine) EGP1510D,H&J

1 660898 1 Clamp - Vee type - Turbocharger outlet2a 660872-4 1 Pipe assembly - turbocharger outlet - jacket lagging EGP1510A&B2b 661131-2 1 Pipe assembly - turbocharger outlet - hard lagging EGP1510C,D,H&J3 660941 2 Clamp - Vee type - Pipes to flexible4 660872-5 1 Flexible pipe5a 660872-6 1 Pipe assembly - flexible to EGP inlet - jacket lagging EGP1510A&B5b 661131-3 1 Pipe assembly - flexible to EGP inlet - hard lagging EGP1510C,D,H&J6 4936201-101 1 Nozzle - Injector EGP

4935801-101 1 Nut - EGP Injector7 660942 1 Clamp - stepped - pipe to EGP8 661148-7 1 Thermister - Inlet9 661148-7 1 Thermister - outlet10a 660872-2 1 EGP Silencer assembly - Euro 4 without NOX sensor (BEIGE engine)10b 661262-1 1 EGP Silencer assembly - Euro 4+ & Euro 5- with NOX sensor (RED engine)

661915 1 NOX sensor - Euro 4+ & Euro 5 11 660943 1 Clamp - stepped - EGP to tailpipe12 660872-7 1 Tailpipe13 660890 7 Mount -high temperature

MCN 110P 14 NutWMA 10SP 14 Washer - PlainWMC 10SP 14 Washer - Spring211401 6 Backing washer

PARTS MANUAL


ENVIRO 400


Unit No: EGP1510A,B,C&D

660872/661131/661262 EGP

FROM TURBO

3

5

16

17

13

4

3

6

7

8

9

10a

11

12

13

14

15

19

20

2526

2

1

22

23

13

21

1324

SOFT LAGGING HARD LAGGING

EURO 4+EURO 5-

10b

18


Unit No: EGP1510A,B,C&D



14 440815 1 Bracket - tailpipe support15 657374 1 “U” Pipe clamp - tailpipe support16 660873 3 Band clamp - EGP mounting17 440649 2 Mounting Bracket - EGP18 661915 1 NOX sensor - Euro 4+ & Euro 5- (RED engine) EGP1510D,H&J19 440652 1 Heat shield assembly - EGP - side20 611005-27 2 Band clamp - heatshield to EGP21 440753 1 Bracket - pipe support - use with jacket lagging Euro 422 441951 1 Bracket - mount - use with hard lagging Euro 4+ & Euro 5-23 441952 1 Bracket - clamp - use with hard lagging Euro 4+ & Euro 5-24 611005-15 1 Clamp - tee bolt type - bracket to pipe25 440774 1 Bracket - pipe support - downpipe to bellhousing

400622-76 4 SpacerMCS 116 25P 2 SetscrewMCN 16SP 2 Nut

26 656160-18 1 “U” Pipe clamp - tailpipe support400622-76 2 Spacer

PARTS MANUAL


ENVIRO 400

EGP - Exhaust Gas Processor System - Insulation Amended:061112

Unit No: EGP1510A,B&C

1

4

2

3

5

660872-11 - E400/A

TURBOOUTLETEGP INLET


Unit No: EGP1510A,B&C

EGP - Exhaust Gas Processor System - Insulation Amended:080107


660872-11 1 KIT - INSULATION JACKETS:

1 660872-12 1 Jacket - turbo pipe outlet (not required for hard lagged pipe)2 660872-13 1 Jacket - flexible pipe outlet3 660872-14 1 Jacket - decomp pipe (not required for hard lagged pipe)4 660872-15 1 Jacket - EGP inlet pipe5 660872-16 13 Clip - insulation jackets

PARTS MANUAL


ENVIRO 400

EGP - Exhaust Gas Processor System - Pipework Amended:070111

Unit No: EGP1510A,B,C,D,E,H&J

AirFilter

Dosing Unit

UREA Tank

1

UREA�IN

UREA�OUT

AIR�IN

MIX�OUT

AR7972

EXHAUSTGAS

PROCESSOR

9

AUXILIARY &SUSPENSIONRESERVOIR

SUPPLYFROM

AIR DRYER

OR

2

3

6

4

5

7

8

8


Unit No: EGP1510A,B,C,D,E,H&J

EGP - Exhaust Gas Processor System - Pipework Amended:070111


660872-3 1 Urea Pipework Kit - comprising:1a 660809-12 1 Doser to Injector pipe - braided1b 660872-8 1 Doser to Injector pipe - nylon

660809-14 * 1 Ferrule - braided pipe660809-15* 1 Nut - braided pipe

2 660872-9 1 Doser to Urea tank - feed3 660872-10 1 Urea Tank to doser unit - return4 - 1 Urea Tank (See separate lists)

MCS-106-25P 4 Setscrew M6 x 16 - tank to frameMCN-506P 4 Nut - self locking

5 660681 1 Air filter660681-2 Elbow660681-1 1 CartridgeMCS-108-55P 4 Setscrew M6 x 16 - tank to frameMCN-508P 4 Nut - self locking

6 4931694 1 Dosing Unit660613-1 1 Connector - “air in”660613-2 1 Connector - “mix out”660613-3 1 Connector - “urea out”660613-4 1 Connector - “urea in”MCS-108-30P 4 Setscrew M6 x 16 - tank to frameMCN-508P 4 Nut - self locking441387 1 Protection plate - doser unit (WPO53220 only) EGP1510A441364 1 Protection plate - doser unit EGP1510B441128 1 Mounting plate - doser unit

7 4936201 1 Nozzle - Injector EGP4935801 1 Nut - EGP Injector

8 660035-2 2 Clip - urea pipe9 661915 1 Nox Sensor

NOTE:IF REPLACING THE INJECTION NOZZLE FITTED WITH ABRAIDED PIPE, A NEW NUT AND FERRULE WILL BE REQUIRED.

PARTS MANUAL


ENVIRO 400

Fuel System - Urea Tank Assembly Amended:070111

Unit No: EGP1510A,B,C - 440724-2. EGP1510D,H - 442431-2

1

3

24

440724-2

6

9

58 10

3

2

9

5

442431-2


Unit No: EGP1510A,B,C - 440724-2. EGP1510D,H - 442431-2

Fuel System - Urea Tank Assembly Amended:120111


440724-2 1 Urea Tank assembly - 19 litres EGP1510A,B&C442431-2 1 Urea Tank assembly - 30.7 litre EGP1510D,H

1a 440725 1 Urea Tank - 19 litres1b 442432 1 Urea Tank - 30 litres

MCS 108 25P 4 SetscrewMCN 508P 4 Nut

2 660739 1 Magnet adaptor3 660751 1 Cap - tank4 660767 1 Plug - drain5 660876 1 Sender unit - urea tank

660876-1 1 “O” ring - sender unit6 660828 1 Filter - Urea7 417362 1 Breather SL21518 442375 1 Bracket - breather mounting9 651787 0.5m Tube - tank to valve

607007 1 Cable tie - tube to tank660035-5 1 Clip tube to breather

10 654242 A/R Tube

Urea Tank Mounting - Wheelarch mounted fuel tank only OL1538-1MCB 108 50P 4 Bolt400622-39 4 SpacerWMC 8SP 4 Washer -springWMA 8SP 4 Washer -Plain

PARTS MANUAL


ENVIRO 400

Fuel System - Urea Tank Assembly - Plastic Amended:070111

Unit No: EGP1510J - 446320-2

16

446242-1

2

3,5,6

4

137,8

9

1011

12

15

14

17

16

18


Unit No: EGP1510J - 446320-2

Fuel System - Urea Tank Assembly - Plastic Amended:070111


1 446240 1 Urea Tank - 30 litresMCS 108 25P 4 SetscrewMCN 508P 4 Nut

2 660876 1 Sender unit - urea tank3 661037 1 Filler neck4 661036 1 Cap - urea tank5 661044 1 “O” ring - filler neck6 660739 1 Magnet adaptor7 661040 1 Plug - drain8 661041 1 “0” ring seal9 446257 1 Gasket - urea sender

10 446256 1 Mounting plate - urea sensor11 MCS 3308 16S 6 Screw - socket head12 658286-1 1 Tank insert13 660828 1 Filter - Urea14 417362 1 Breather15 442375 1 Bracket - breather mounting16 651787 0.5m Tube - tank to valve

660035-5 1 Clip tube to breather17 654242 A/R Tube

447097 1 Clamp - urea tank

PARTS MANUAL


ENVIRO 400

Fuel System - Urea Tank Assembly - Identic Amended:070308

Unit No: OL1536-1,OL1536-2

5/6

23

4

7

89

OL1536-1

1


Unit No: OL1536-1,OL1536-2

Fuel System - Urea Tank Assembly - Identic Amended:070308


Used on and up to Chassis No 4306441310 1 Urea Tank assembly - Used on Euro 4 OL1536-1

1a 441308 1 Urea Tank Used on & after Chassis No 4307

442482 1 Urea Tank assembly - Used on Euro 4+ OL1536-21b 442483 1 Urea Tank

2 660739 1 Magnet adaptor3 660751 1 Cap - tank4 660767 1 Plug - drain5 660876 1 Sender unit - urea tank6 660828 1 Filter - Urea7 441784 1 Urea sensor - identic filler8 441299 1 Adaptor plate - urea sensor9 441326 1 Gasket - adaptor plate

10 MCS 3604 10 8 Capscrew

PARTS MANUAL


ENVIRO 400

Fuel Tank Assembly - Staircase Amended:140907

Unit No: FS1514A&D. FS1515A,E,F&J

2322 21

24

1

2

3

6,7

8

440866/442220-STD

14

16

14

10

15

17

1213

15

14

16

15

14

16

101213

15

1416

14

19

10

18

204

9

13

11

4

8

5


Unit No: FS1514A&D. FS1515A,E,F&J

Fuel Tank Assembly - Staircase Amended:140907


440866 1 Fuel tank assembly 442220 1 Fuel tank assembly - stainless steel FS1515E

1 440367 1 Fuel tank2 603678 2 Seal3 5349-3 2 Plug 4 657829 2 Gasket5 441020 1 Filler neck assembly6 658137 1 Filler cap

650189 A/R Loctite7 658137-1 2 Washer8 MCS 106 16P 12 Setscrew9 440783 1 Bracket - tank support - “Z”10 438628 3 Rubber strip - tank isolator11a 440784 1 Angle bracket - tank support rear - 19 litre Urea Tank - Euro 411b 442414 1 Angle bracket - tank support rear - 30.7 litre Urea Tank - Euro 4+12 WMA 8SP 18 Washer - plain13 MCN 508P 15 Nut - full 14 652361 19 Washer - large15 10 MCB 108 50 D 9 Bolt - tank mounting16 432210 9 Mounting rubber17 MCS 108 25P 9 Setscrew - support brackets18 439230 1 Plate - top mounting19 439228 1 Tank mounting - top20 426083 1 Blanking plate

PARTS MANUAL


ENVIRO 400

Fuel Tank Assembly - Identic Filler Amended:140907

Unit No: FS1514C&F. FS1515C&H

AR7717-440766

1

2

3

6,7

8

AR7717-440766

14

16

14

10

15

17

1213

15

14

16

15

14

16

101213

15

1416

14

19

10

18204

9

13

11

23

21

4

8

23 2224

2526


Unit No: FS1514C&F. FS1515C&H

Fuel Tank Assembly - Identic Filler Amended:140907


440766 1 Fuel tank assembly - Identic:

1 440367 1 Fuel tank2 603678 2 Seal3 5349-3 2 Plug 4 657829 2 Gasket5 441026 1 Filler neck assembly - Identic6 658137 1 Filler cap

650189 A/R Loctite7 658137-1 2 Washer8 MCS 106 16P 12 Setscrew9 440783 1 Bracket - tank support - “Z”

10 438628 3 Rubber strip - tank isolator11a 440784 1 Angle bracket - tank support rear - 19 litre Urea Tank - Euro 411b 442414 1 Angle bracket - tank support rear - 30.7 litre Urea Tank - Euro 4+

12 WMA 8SP 18 Washer - plain13 MCN 508P 15 Nut - full 14 652361 19 Washer - large15 10 MCB 108 50 D 9 Bolt - tank mounting16 432210 9 Mounting rubber17 MCS 108 25P 9 Setscrew - support brackets18 439230 1 Plate - top mounting19 439228 1 Tank mounting - top20 440789 1 Plate - sender mounting - Identic21 660708-1 1 Identic level sensor c/w cable22 656706-5 1 Coupling - spill free23 656709-9 1 Hose - re-inforced24 656706-10 1 Hose clip25 MCS 3605 16P 2 Screw26 WMC 5SP 2 Washer - spring

PARTS MANUAL


ENVIRO 400

Fuel Tank Assembly - Posilock Filler Amended:140907

Unit No: FS1514E. FS1515B&G

AR7717-440766

1

2

3

21

AR7717-440766

14

16

14

10

15

17

1213

15

14

16

15

14

16

101213

15

1416

14

19

10

18

204

9

13

11

4

8

5

7

6

8

22


Unit No: FS1514E. FS1515B&G

Fuel Tank Assembly - Posilock Filler Amended:260509


441037 1 Fuel tank assembly - posilock:

1 441733 1 Fuel tank2 603678 1 Seal3 5349-3 1 Plug 4 657829 2 Gasket5 441901 1 Filler neck assembly - Posilock6 658570-1 1 Filler cap - posilock flip cap

658570-3 1 Filler cap658570-4 1 Dust seal658570-5 1 Spring clip

7 657002 1 Filler adaptor8 MCS 106 16P 12 Setscrew9 440783 1 Bracket - tank support - “Z”

10 438628 3 Rubber strip - tank isolator11a 440784 1 Angle bracket - tank support rear - 19 litre Urea Tank - Euro 411b 442414 1 Angle bracket - tank support rear - 30.7 litre Urea Tank - Euro 4+

12 WMA 8SP 18 Washer - plain13 MCN 508P 15 Nut - full 14 652361 19 Washer - large15 10 MCB 108 50 D 9 Bolt - tank mounting16 432210 9 Mounting rubber17 MCS 108 25P 9 Setscrew - support brackets18 439230 1 Plate - top mounting19 439228 1 Tank mounting - top20 439512 1 Valve mounting plate21 659405 1 Pressure relief valve assembly

659405-1 1 Gasket22 660965 1 Level control valve assembly

657059-1 1 Gasket23 661102 1 Tube - posilock filler

661130 1 Vent kit - body

PARTS MANUAL


ENVIRO 400

Fuel Tank Assembly - Wheelarch Amended:231008

Unit No: FS1514G. FS1515D&L. OL1521-6

FS1514G-434911

1

4,5

14

15

16

12

1718

3

6

62

37

8

910

11

13

15

14

16

19


Unit No: FS1514G. FS1515D&L. OL1521-6

Fuel Tank Assembly - Wheelarch Amended:100209


434911 1 Fuel tank assembly - steel FS1514G/FS1515D434913 1 Fuel tank assembly - stainless steel FS1515L5349-3 1 Plug603678 1 Seal

1a 434914 1 Fuel tank - steel2a 434932 1 Filler neck assembly1b 434915 1 Fuel tank - stainless steel2b 434934 1 Filler neck assembly

3 657829 1 Gasket - blanking plate4 658137 1 Filler cap

650189 A/R Loctite5 658137-1 2 Washer6 MCS 106 20P 6 Setscrew

7a 426083 1 Plate - blanking8 431429 1 Plinth - tank support - rear9 MCS 108 25P 3 Setscrew - support brackets

10 WMA 8SP 3 Washer - plain11 MCN 508P 3 Nut - full 12 427829 1 Rubber strip - tank isolator - rear13 427827 1 Rubber strip - tank isolator - front14 10 MCB 108 50 D 6 Bolt - tank mounting15 652361 6 Washer - large16 432210 6 Mounting rubber17 WMA 8SP 6 Washer - plain18 MCN 508P 6 Nut - full

FUEL TANK SENDER UNIT OL1521-67b 439123 1 Plate - fuel sender19 660534-3 1 Fuel tank sender unit

445420 1 Harness - sender unit

PARTS MANUAL


ENVIRO 400

Fuel Tank Assembly - Wheelarch - Remote identic Filler Amended:100209

Unit No: FS1515P

FS1515P-445315

1

4,5

14

15

16

12

1718

3

6

62

37

8

910

11

13

15

14

16

20

21

19

22


Unit No: FS1515P

Fuel Tank Assembly - Wheelarch - Remote Identic Filler Amended:130111


445315 1 Fuel tank assembly - identic - remote5349-3 1 Plug603678 1 Seal

1 434914 1 Fuel tank - steel2 434932 1 Filler neck assembly3 657829 1 Gasket - blanking plate4 658137 1 Filler cap

650189 A/R Loctite5 658137-1 2 Washer6 MCS 106 16P 12 Setscrew7 445316 1 Plate - Identic remote8 447259 1 Plinth - tank support - rear SL22969 MCS 108 25P 3 Setscrew - support brackets

10 WMA 8SP 3 Washer - plain11 MCN 508P 3 Nut - full 12 427829 1 Rubber strip - tank isolator - rear13 427827 1 Rubber strip - tank isolator - front14 10 MCB 108 55 D 6 Bolt - tank mounting15 652361 6 Washer - large16 432210 6 Mounting rubber17 WMA 8SP 6 Washer - plain18 MCN 508P 6 Nut - full 19 661741 1 Kit - Identic filler c/w clips20 661742 1 Filler hose21 661743 1 Breather hose22 661740 1 Kit - identic comprising:

658763-1 1 Armour hose658763-4 1 Weight658763-2 1 Level sensor656818-5 1 Hose clip

PARTS MANUAL


Fuel System Pipework - Staircase Amended:050407

Unit No: FS1514A,C,D,E&F

3

FS1514A-F

FUEL SHUT OFF VALVE

4

26

31

5 12

11

9

1,2

14

13

15

24

18

16

17

13

10

7

25

7

6

8

23

20

19

20

1824

FUEL SHUT OFF VALVES

WITHOUT FUELSHUT OFF VALVE


3029

32

10 mm BLACK

21

ENGINE FUEL

DISTRIBUTIONPOINT

12 mm BLACK

41

40

37 38 39

SUPPLY

33

3334

35

36

RETURN

27,28

ENVIRO 400





Used on & up to Chassis No 4191

1 656181 1 Elbow - tank feed2 655832-3 1 Sleeve - 12mm3 654993 A/R Pipe - nylon - black - 12mm4 660535-8 1 Connector - feed

655832-3 1 Sleeve - 12mm5 654916-7 1 Adaptor6 441175 1 Pipe assembly 7 651936 1 Adaptor8 441176 1 Pipe assembly 9 441177 1 Pipe assembly - fuel filter inlet

10 660151 1 Adaptor pipe to valve11 658188 1 Valve12 660744 1 Adaptor13 660643-1 2 Adaptor - fuel filter inlet / outlet14 659523 1 Fuel filter

659523-1 1 Element - fuel filter659523-2 1 Harness - sensor659523-3 1 Sensor - water in fuel660975 2 Plug - blanking

15 441114-1 1 Hose assembly - 16 655443 1 Bulkhead connector17 441078 1 Bracket - bulkhead connector mounting18 441178 1 Pipe assembly - to engine fuel manifold19 654909-3 1 Connector - manifold inlet20 661099 2 Reducer21 - - “O” ring22 - - “O” ring23 654933-3 1 Elbow - manifold outlet

PARTS MANUAL


ENVIRO 400



3

FS1514A-F

FUEL SHUT OFF VALVE

4

26

31

5 12

11

9

1,2

14

13

15

24

18

16

17

13

10

7

25

7

6

8

23

20

19

20

1824

FUEL SHUT OFF VALVES



3029

32

10 mm BLACK

21

ENGINE FUEL

DISTRIBUTIONPOINT

12 mm BLACK

41

40

37 38 39

SUPPLY

33

3334

35

36

RETURN

27,28





24 438724-2 1 Hose assembly - from engine25 660535-6 1 Connector - return26 654992 A/R Pipe - nylon - black - 10mm27 655842 1 Elbow - tank return28 655832-1 1 Sleeve - 10mm29 417362 1 Breather valve30 655164 1 Elbow - breather31 651548 A/R Pipe - nylon - black - 8mm32 654242 A/R Pipe - PVC - clear - 6mm33 603678 2 Bonded seal34 650133 1 Connector35 661076 1 Valve - non return36 655842 1 Connector

655832-1 1 Sleeve - 10mm37 660136 1 Elbow - tank supply AR790438 660854-1 1 Connector

655832-3 1 Sleeve - 12mm39 660855 1 Valve - solenoid - fuel shut off40 654927-3 1 Adaptor41 658204 1 Connector

PARTS MANUAL


ENVIRO 400

Fuel System Pipework - Wheelarch Amended:050407

Unit No: FS1514G

5

FS1514C

FUEL SHUT OFF VALVE

6

26

7

14

13

11

16

15

17

24

20

18

19

15

12

9

25

9

8

10

23

22

21

22

2024

3332

35

10 mm BLACK

21

ENGINE FUEL

DISTRIBUTIONPOINT

12 mm BLACK

325L

31

30

27 28 29

SUPPLY

1

12

3

4

34

RETURN


Unit No: FS1514G



Used on & up to Chassis No 41911 603678 2 Bonded seal2 650133 1 Connector3 661076 1 Valve - non return4 655842 1 Connector

655832-1 1 Sleeve - 10mm5 654993 A/R Pipe - nylon - black - 12mm6 660535-8 1 Connector - feed

655832-3 1 Sleeve - 12mm7 654916-7 1 Adaptor8 441175 1 Pipe assembly 9 651936 1 Adaptor

10 441176 1 Pipe assembly 11 441177 1 Pipe assembly - fuel filter inlet12 660151 1 Adaptor pipe to valve13 658188 1 Valve14 660744 1 Adaptor15 660643-1 2 Adaptor - fuel filter inlet / outlet16 659523 1 Fuel filter

659523-1 1 Element - fuel filter659523-2 1 Harness - sensor659523-3 1 Sensor - water in fuel660975 2 Plug - blanking

17 441114-1 1 Hose assembly - 18 655443 1 Bulkhead connector19 445491 1 Bracket - bulkhead connector mounting20 441178 1 Pipe assembly - to engine fuel manifold21 654909-3 1 Connector - manifold inlet22 661099 2 Reducer

PARTS MANUAL


ENVIRO 400


Unit No: FS1514G

5

FS1514C

FUEL SHUT OFF VALVE

6

26

7

14

13

11

16

15

17

24

20

18

19

15

12

9

25

9

8

10

23

22

21

22

2024

3332

35

10 mm BLACK

21

ENGINE FUEL

DISTRIBUTIONPOINT

12 mm BLACK

325L

31

30

27 28 29

SUPPLY

1

12

3

4

34

RETURN


Unit No: FS1514G



23 438724-2 1 Elbow - manifold outlet24 438724-2 1 Hose assembly - from engine25 660535-6 1 Connector - return

655832-1 1 Sleeve - 10mm26 654992 A/R Pipe - nylon - black - 10mm27 660136 1 Elbow - tank supply AR790428 660854-1 1 Connector

655832-3 1 Sleeve - 12mm29 660855 1 Valve - solenoid - fuel shut off30 654927-3 1 Adaptor31 658204 1 Connector32 417362 1 Breather valve33 655164 1 Elbow - breather34 651548 A/R Pipe - nylon - black - 8mm35 654242 A/R Pipe - PVC - clear - 6mm

441671 1 Harness - fuel cut out valve

PARTS MANUAL


ENVIRO 400

Fuel System Pipework - Wheelarch & Staircase Amended:060308

Unit No: FS1515A,B,C,D&L

FS1515A-C

FUEL SHUT OFF VALVE

3

1

2

4

5

TO FUEL PUMP

RETURNFROMFUELPUMP

10 mm BLACK

21

ENGINE FUEL

DISTRIBUTIONPOINT

12 mm BLACK

Used on & after Chassis No 4192



Fuel System Pipework - Wheelarch & Staircase Amended:060308


Used on & after Chassis No 41921 441342 1 Bulkhead connector

654960 1 Locknut2 4943865-101 1 Connector - bulkhead fitting3 4941856-101 1 Hose assembly - bulkhead fitting to fuel pump4 661099 1 Reducer5 654909-3 1 Connector

All other parts as previous pages

PARTS MANUAL


ENVIRO 400

Fuel System Pipework - Engine Fuel Filter Amended:110111


'C'

'B'

'B''C'

'A'

TYPICAL CLIPPING

FUEL PUMP

6

6

3

4

1

4

3

2

2

2

3

42

2

34

5

6

78

14

10

9

11

12

13

15

Used on & after Chassis No 4192



Fuel System Pipework - Engine Fuel Filter Amended:110111


Used on & after Chassis No 41921 441433 1 Plate - fuel hose mounting2 661169 5 Stud - sump3 WMA 6SP 5 Washer - plain4 MCN 506P 5 Nut - self locking5 401825 1 Bracket - hose mounting6 418888 2 Bracket - hose mounting7 656844 5 Spacer8 610808-1 5 Cable tie9 442111 1 Spacer plate - filter mounting

10 400622-121 3 Spacer - filter mounting plate11 MCB 112 45P 2 Bolt12 MCB 112 35P 2 Bolt13 WMC 12SP 2 Washer - Spring14 MCN 512P 2 Nut - self locking15 4941856-101 2 Hose assembly - supply / return

PARTS MANUAL


ENVIRO 400

Hydraulic System Amended:110407

Unit No: HS1517A&C. HS1518A&C

OILCOOLER

1

2

32

FAN PUMP

STEER PUMPSTEERING

BOX

OIL FILTER

FAN MOTOR

TESTPOINT

TESTPOINT

STEERING

FAN

8,91013111312

2221 1323 26/2724

40 41

3637

14

5

44

20

45

6

38

15

1617

18

28

4649

50

33

28

3

35

4

4 34

7

19

2513

29/30

31

42

43

43

47 4748

52

39

39

51

53

AR7934/AR8167





1 655644 1 Steering reservoir assembly (see separate list)2 441116-1 1 Hose assembly - reservoir to pipe

656818-7 2 Clip3a 440988 1 Pipe assembly - reservoir to tandem pump elbow3b 440990 1 Pipe assembly - suction pipe - steering - drain valve type

658445-6 1 Drain valve4 656732 2 Elbow - tandem pump5 661123 1 Tandem pump

657514-1 1 Seal kit - tandem pump658063 1 Gasket - pump to compressor439972 1 Bracket - tandem pump support - for use with original pump 659674441897 1 Bracket - tandem pump support - for use with later pump 661123UFN 506AP 2 Nut - pump to bracket WLA 6SP 2 Washer - plain - pump to bracketMCS 112 25P 2 Bolt - bracket to engineWLA 12SP 2 Washer - bracket to engineWLC 12SP 2 Washer - bracket to engine

6 653810 1 Adaptor - steering pump outlet7 440234 1 Hose - tandem pump to connector

443322 1 Support plate610029-4 1 “P” clip - hose660217-1 1 “P” clip - high temperature - pipe

8 654957-1 1 Connector - hose to pipe9 654958-1 1 Locknut

10 441228 1 Pipe assembly - rear

NOTE:Tandem pump 661123 has replaced Tandem pump 659684. To fit this later Tandem pump, support bracket 439972is replaced by 441897. The fan motor return fitting, item 34, 656251-9 is replaced by 656251-10.SL2130 is available for this conversion.

PARTS MANUAL


ENVIRO 400



OILCOOLER

1

2

32

FAN PUMP

STEER PUMPSTEERING

BOX

OIL FILTER

FAN MOTOR

TESTPOINT

TESTPOINT

STEERING

FAN

8,91013111312

2221 1323 26/2724

40 41

3637

14

5

44

20

45

6

38

15

1617

18

28

4649

50

33

28

3

35

4

4 34

7

19

2513

29/30

31

42

43

43

47 4748

52

39

39

51

53

AR7934/AR8167





11a 422385 1 Pipe assembly - mid (5.25 m wheel base) HS1517A11b 426612 1 Pipe assembly - mid (5.95 m wheel base) HS1517C12 441229 1 Pipe assembly - front13 654955-1 4 Adaptor 14 659321 1 Adaptor15 440846 1 Hose assembly - pipe to test point elbow16 660934 1 Elbow17 656394 1 Test point18 659633 1 Steering Gear (See Section 7)19 658379 1 Seal20 659632 1 Adaptor21 436968 1 Hose assembly - steering box to connector22 660935 1 Adaptor - hose to return pipe23 422386 1 Pipe assembly - front

24a 422385 1 Pipe assembly - mid (5.25 m wheel base) HS1517A24b 426612 1 Pipe assembly - mid (5.95 m wheel base HS1517C

25 441230 1 Pipe assembly - rear26 654957-1 1 Adaptor - bulkhead

441053 1 Bracket - bulhead connector27 654958-1 1 Lock nut28 441231 1 Pipe assembly - rear29 654957-1 1 Adaptor - bulkhead30 654958-1 1 Lock nut31 440845 1 Hose assembly - pipe to steering reservoir

656818-3 2 Clip32 441117-1 1 Hose - reservoir to pipe

33a 440987 1 Pipe assembly - suction pipe - fan33b 440989 1 Pipe assembly - suction pipe - fan - drain valve type

658455-6 1 Drain valve - located near tandem pump

PARTS MANUAL


ENVIRO 400



OILCOOLER

1

2

32

FAN PUMP

STEER PUMPSTEERING

BOX

OIL FILTER

FAN MOTOR

TESTPOINT

TESTPOINT

STEERING

FAN

8,91013111312

2221 1323 26/2724

40 41

3637

14

5

44

20

45

6

38

15

1617

18

28

4649

50

33

28

3

35

4

4 34

7

19

2513

29/30

31

42

43

43

47 4748

52

39

39

51

53

AR7934/AR8167





34 656251-10 1 Adaptor - outlet to fan motor Replaces 656251-935 440843 1 Hose assembly - tandem pump to fan motor36 659323 1 Tee piece37 656394 1 Test point38 659322 1 Adaptor - fan motor drain39 440842 1 Hose assembly - fan motor drain40 661124 1 Fan motor

658086-1 1 Seal kit - fan motor41 656612-2 1 Connector42 441232 1 Pipe assembly - fan motor to oil cooler43 660884-1 2 Elbow - oil cooler44 440690-1 1 Oil cooler45 441233 1 Pipe assembly - oil cooler to filter46 660645-1 1 Adaptor - oil filter47 603680 2 Seal - adaptor - oil filter48 656730 1 Oil filter

656730-1 1 Element - oil filter49 606122 1 Adaptor - oil filter50 440844 1 Hose - filter to reservoir - push on

656818-7 3 Clip51 442447 1 Hose assembly - filter to reservoir52 442100 1 Fan drive reservoir assembly (see separate list)53 603676 1 Dowty washer

Hydraulic pipe support427379 6 Bracket - 90° - Isolator bracket assembly427380 1 Bracket - 90°658135 1 Isolator

PARTS MANUAL


ENVIRO 400

Steering Reservoir Assembly Amended:

Unit No:655644


Unit No: 655644

Steering Reservoir Assembly Amended:


655644 1 Hydraulic tank assembly1 655644-2 1 Reservoir body2 655644-6 1 Dipstick3 655644-1 1 Filter element4 655644-3 1 Bolt5 655644-5 1 Filler cap6 655644-4 1 Sealing washer

440778 1 Mounting bracket - steering reservoir / fan reservoir611005-11 2 Clamp - tee bolt type - reservoir to bracket440736 1 Oil filler - drip tray

441253 1 Label - steering reservoir levels

When replacing the earlier Hydraulic tank assembly

PARTS MANUAL


ENVIRO 400

Hydraulic Fan Reservoir Assembly Amended:120407

Unit No:442100

2

3

1442100


Unit No: 442100

Hydraulic Fan Reservoir Assembly Amended:120111


442100 1 Hydraulic tank assembly1 442101 1 Hydraulic tank 2 660344 1 Filler cap3 661942 1 Level indicator sight gauge

441252 1 Label - sight glass - “max / min”

440778 1 Mounting bracket - steering reservoir / fan reservoir611005-16 2 Clamp - tee bolt type - reservoir to bracket440736 1 Oil filler - drip tray

441251 1 Label - fan reservoir levels

SL2142 - Hydraulic Fan Reservoir Filler extension. SK11400442095 1 Filler pipe661238 1 Gasket - filler neckST 110 5P 3 Screw 3NmWMC-5SP 3 Washer - spring

NOTEWhen replacing the earlier Hydraulic tank assembly with the latest 442100an elbow , 650441, will be required to connect the push on hose to the newthreaded boss using the existing hose clip.

PARTS MANUAL


ENVIRO 400

Engine and Mounting - Voith Transmission Amended:210110

Unit No: EM1513A,C&E.EM1514A,EM1515A

EM1513-E400

17

6

14

11

13

12

15

16

30 31

7

15

16

6

13 2

4 5

13,14

10

9

11

Coupling to Flywheel

3233

36

38

EM1513-E400

18

24

292827

19

21

22

23

22 21 20

2625

3031

Voith Transnmission to engine bellhousing

8

3435

3637

12


Unit No: EM1513A,C&E.EM1514A,EM1515A&EM1516A



Used on and up to Chassis No 4227661241 1 Engine - ISBe 6 Cylinder - Euro 4 - BEIGE ~ Voith transmission EM1513A,C

Used on and after Chassis No 4228661476 1 Engine - ISBe 6 Cylinder - Euro 4+ - RED ~ Rationalised - Voith/ZF EM1514A

Used on and after Chassis No 4689661541 1 Engine - ISBe 6 Cylinder - Euro -5 ~ RED - Voith/ZF EM1516A

659268 1 Starter motor - Used on and up to Chassis No 4082 & 4105 - 4115 EM1513A661096 1 Starter motor - Used on and after Chassis No 4083 - 4104 & 4116 EM1513C,E,F. EM1514A &

EM1515C1 MCB 122 180P 1 Bolt - upper - engine stay - M222 425867 1 Engine stay assembly

425704 1 Engine stay3 657138 1 Bush - engine stay4 WMA 22SP 1 Washer - plain5 MCN 722P 1 Nut - self locking - M226 412711 2 Rebound washer - upper7 440364 1 Engine mounting bracket - RH - Voith8 440363 1 Engine mounting bracket - LH - Voith

9a MFB 114 50P 8 Bolt - engine mounting bracket9b MFB 114 80P 4 Bolt - engine mounting bracket10 WMC 14SP 8 Washer - spring 11 657639 2 Engine mount - transmission12 MCS 112 40P 4 Setscrew - mount to bracket13 WMA 12SP 4 Washer - spring14 MCN 512P 4 Nut - self locking15 437801 2 Rebound washer - lower16 MFN 524P 2 Nut - self locking - M2417 MFB 124 190P 1 Bolt - engine mounting18 439569 1 Bracket - engine mounting19 MCB 112 90P 2 Bolt - Bracket to engine 20 MCS 112 30P 6 Setscrew - Bracket to engine

PARTS MANUAL


ENVIRO 400



EM1513-E400

17

6

14

11

13

12

15

16

30 31

7

15

16

6

13 2

4 5

13,14

10

9

11

Coupling to Flywheel

3233

36

38

EM1513-E400

18

24

292827

19

21

22

23

22 21 20

2625

3031

Voith Transnmission to engine bellhousing

8

3435

3637

12





21 WMC 12SP 8 Washer - spring22 WMA 12SP 8 Washer - Plain

606631 A/R Loctite - 27023 660743 1 Engine mount24 MCB 112 40P 4 Bolt - mount to engine bracket 40 - 45 lbs ft25 MCN 512P 4 Nut - self locking26 WMA 12SP 4 Washer - plain27 MFS 116 55P 2 Screw - mount to frame28 WMC 16SP 2 Washer - spring29 WMA 16SP 2 Washer - plain30 MCB 110 40P 11 Bolt - transmission to bellhousing 50 Nm

606152 A/R Loctite - HO 24231 659314-5 11 Washer - hardened32 660878-5 11 Bolt - flywheel adaptor to flywheel - Voith33 660281-4 11 Washer - plain 50 Nm34 439797 1 Skirt angle - RH (For further frame deatils see Page 6.22 - 6.23)35 426497 1 Plate - tapped36 MCS 110 30P 9 Setscrew - skirt37 WMC 10SP 9 Washer - spring38 MCN 510P 6 Nut - self locking

ENGINE BREATHER TUBE EXTENSION - SL2152442426 1 Tube - engine breather656818-5 1 Hose clip610029-4 1 “P”clipWMA 8SP 1 Washer

431894 1 Plug - bottom bellhousing hole

PARTS MANUAL


ENVIRO 400

Engine and Mounting - ZF Transmission Amended:210110

Unit No: EM1513B,D&F.EM1514A,EM1515A

17

6

14

11

13

12

15

16

30 31

7(8)

15

16

6

13 2

45

12

10

9

11

14

34

36

EM1513-E400-ZF

18

24

292827

19

21

22

23

22 21 20

2625

3233

3435

13





Used on and up to Chassis No 4227660558 1 Engine - Cummins ISBe 6 cylinder - Euro 4 - BEIGE - ZF transmission EM1513B&D

Used on and after Chassis No 4228661476 1 Engine - ISBe 6 Cylinder - Euro 4+ - RED ~ Rationalised - Voith/ZF EM1514A (661261)

Used on and after Chassis No 4689661541 1 Engine - ISBe 6 Cylinder - Euro -5 ~ RED - Voith/ZF EM1516A

659268 1 Starter motor - Used on and up to Chassis No 4082 & 4105 - 4115 EM1513B661096 1 Starter motor - Used on and after Chassis No 4083 - 4104 & 4116 EM1513D,E,F. EM1514A&

EM1515C1 MCB 122 180P 1 Bolt - upper - engine stay - M222 425867 1 Engine stay assembly

425704 1 Engine stay3 657138 1 Bush - engine stay4 WMA 22SP 1 Washer - plain5 MCN 722P 1 Nut - self locking - M226 412711 2 Rebound washer - upper7 440342 1 Engine mounting bracket - RH - ZF8 440341 1 Engine mounting bracket - LH - ZF

9a MFB 114 50P 8 Bolt - engine mounting bracket9b MFB 114 80P 4 Bolt - engine mounting bracket10 WMC 14SP 8 Washer - spring 11 657639 2 Engine mount - transmission12 MCS 112 40P 4 Setscrew - mount to bracket13 WMA 12SP 4 Washer - spring14 MCN 512P 4 Nut - self locking15 437801 2 Rebound washer - lower16 MFN 524P 2 Nut - self locking - M2417 MFB 124 190P 1 Bolt - engine mounting18 439569 1 Bracket - engine mounting19 MCB 112 90P 2 Bolt - Bracket to engine 20 MCS 112 30P 6 Setscrew - Bracket to engine

PARTS MANUAL


ENVIRO 400



17

6

14

11

13

12

15

16

30 31

7(8)

15

16

6

13 2

45

12

10

9

11

14

34

36

EM1513-E400-ZF

18

24

292827

19

21

22

23

22 21 20

2625

3233

3435

13





21 WMC 12SP 8 Washer - spring22 WMA 12SP 8 Washer - Plain

606631 A/R Loctite - 27023 660743 1 Engine mount24 MCB 112 40P 4 Bolt - mount to engine bracket 40 - 45 lbs ft25 MCN 512P 4 Nut - self locking26 WMA 12SP 4 Washer - plain27 MFS 116 55P 2 Bolt - mount to frame 40 - 45 lbs ft28 WMC 16SP 2 Washer - spring29 WMA 16SP 2 Washer - plain30 MCB 110 40P 12 Bolt - flywheel adaptor to flywheel - ZF

606152 A/R Loctite - HO 24231 659314-5 12 Washer - hardened32 439797 1 Skirt angle - RH (For further frame deatils see Page 6.22 - 6.23)33 426497 1 Plate - tapped34 MCS 110 30P 9 Setscrew - skirt35 WMC 10SP 9 Washer - spring36 MCN 510P 6 Nut - self locking

ENGINE BREATHER TUBE EXTENSION - SL2152442426 1 Tube - engine breather656818-5 1 Hose clip610029-4 1 “P”clipWMA 8SP 1 Washer

431894 1 Plug - bottom bellhousing hole

PARTS MANUAL


ENVIRO 400

Engine and Mounting - Oil Filler Amended:080708

Unit No: EM1513A&B

ENGINE OIL

ENGINE�OIL

3 6

1

4

2

5


Unit No: EM1513A&B

Engine and Mounting - Oil Filler Amended:290113


1 68243-26 1 Cap - oil filller2 440762 1 Filler neck / dipstick support bracket

MCS 104 20P 3 Screw - neck to drip trayWMA 4SP 3 Washer - plainMCN 504P 3 NutMCS 108 50P 1 Bolt - neck to drip tray

400622-39 1 Spacer 610029-4 1 “P” clip

MCN 508P 1 Nut3 659637 1 Hose - oil filler pipe

656818-5 1 Clip - hose to engine656818-9 1 Clip - hose to filler

4 440736 1 Oil filler drip tray5 B37294 0.065M Edge trim

6 419966 1 Label - engine oil filler

FOR DIPSTICK, SEE ENGINE SUNDRIES SECTION PAGE 2.79

PARTS MANUAL


ENVIRO 400

Engine Service Sundries Amended:070708

Unit No:EM1513B,D&F.EM1514A,EM1515A

3

FUEL/WATERFUEL FUEL 8

9

5

1 2

7

4

6

10 11 12



Engine Service Sundries Amended:110111


1 660558-1 1 Gasket - Sump 2 660558-2 1 Sump3 658455-7 1 Drain valve - sump (option) OL1534-1

660558-3 1 Sump plug 660558-4 1 Seal - sump plug

4 660558-5 1 Thermostat c/w seal660558-6 1 Seal - thermostat

5 DP010206 1 Fuel filter - engine mounted6 659523-1 1 Fuel / water filter - frame mounted

659523-2 1 Harness - sensor659523-3 1 Sensor - water in fuel

7 DP010205 1 Engine Oil Filter8 660558-11 1 Dipstick & tube assembly - locking - yellow top* Re-use block adaptor

660558-12 1 Dipstick - locking - yellow top660558-13 1 Dip tube - locking dipstick - with block adaptor

9 3289001-101 1 Alternator Drive Belt - See Altenator Section P2.8110 4899226 1 Gasket - valve cover11 660838-1 1 Compressor12 660558-9 1 Cap - oil filller

* Replaces 445418 / 445419

For further infomation please contact parts ordering, quoting your engine serial number.

PARTS MANUAL


ENVIRO 400

Alternator Mounting Amended:


87

6

12

5

EM1513

3

4

2

1

11

7

7

10

9



Alternator Mounting Amended:240209


Used on & upto Chassis No 42271a 659717 1 Alternator AC172RA - 140A

2a 3289001-101 1 Belt - alternator

3a 432296 1 Pulley

Used on & after Chassis No 42281b 661098 1 Alternator AC172RA - 155A

2b 4988883-101 1 Belt - alternator

3b 3281533-101 1 Pulley

4 651274-8 1 Nut - pulley

5 654863-14 1 Washer - pulley nut

6 MCB 116 190P 1 Bolt - alternator pivot

7 WMA 16SP 3 Washer - plain

8 MCN 516P 2 Nut

9 MCB 116 60P 1 Bolt - alternator pivot

10 WMC 16SP 1 Washer - spring

11 658800-2 1 Alternator duct assembly

12 656818-12 1 Clip - alternator ducting

654200 2 Rubber boot

PARTS MANUAL


ENVIRO 400

Saloon Heater Pipework Amended:100706

Unit No:AL1542-5

LOWER

UPPER

AR7986

ENGINE

FEED

RETURN

FEED

RETURN

GEARBOX TO WATERPUMPRETURN PIPE

REAR HEATER PIPEWORK

FRONT HEATER PIPEWORK

FEED

RETURN

2

3

2

6

54

1

2

7

8

10

1110

5 14

15

16

18

17

2

10 13

12


Unit No:AL1542-5

Saloon Heater Pipework Amended:130209


1 439981 1 Pipe - return - front of wheel arch2 434250-2 4 Hose - straight

656818-7 8 Clip3 441170 1 Pipe - return - rear of wheel arch4 441163 1 Pipe - elbow to hose 5 434249-2 2 Hose - elbow

656818-7 4 Clip6 441161 1 Pipe - return to gate valve / elbow7 441160 1 Pipe - feed - to elbow8 434249-8 1 Elbow - heater supply9 441166 1 Pipe - elbow to valve

10 658650 1 Valve - heater supply11 441165 1 Pipe - heater feed (See cooling system for further details)12 434249-1 1 Elbow - heater supply

656818-7 2 Clip13 429610 1 Pipe - elbow to gate valve14 441162 1 Pipe - feed - elbow to hose15 441169 1 Pipe - feed - rear of wheel arch16 439980 1 Pipe - feed - front of wheel arch17 439955 1 Pipe - feed - front LH wheel arch18 439956 1 Pipe - return - front RH wheel arch

FOR FURTHER DETAILS PLEASE REFER TO E400 BODY SPARES MANUAL

PARTS MANUAL


ENVIRO 400

Air Conditioning Amended:

Unit No:AL1532-1

1

4

8

6

7

12

8

95,10

2 7

AL1532-1

6

14

15

8

8

3

11

10

13


Unit No:AL1532-1

Air Conditioning Amended:


1 433782 1 Pulley2 439569 1 Engine mounting bracket3 441199 1 Compressor mounting bracket assembly

439029 1 Bush - “top hat”439030 3 Bush - plain

4 MCB 112 40P 2 Setscrew5 MCB 112 35P 1 Setscrew6 MCS 3610 40 3 Cap screw7 MCN 510P 6 Nut8 WMA 10SP 12 Washer - plain9 MCS 3610 50 1 Cap screw

10 WMC 12SP 3 Washer - spring11 433505 2 Stay bracket12 MCS 3610-20P 9 Bolt - flanged13 7040800N01 1 Compressor

7040801N01 1 Belt - compressor14 445062 1 Screw15 445063 1 Screw

441103 1 Block air con supportMCS 112 100P 1 Bolt - air con bracket to blockMCS 108 40P 1 Bolt - block to bracketWMC 8SP 1 Washer - spring


Contents

Transmission Amended:

Voith D864.5E TransmissionTransmission - Voith . . . . . . . . . . . . . . . Page 3.2 - 3

ZF Transmission - 5HP502Transmission - ZF . . . . . . . . . . . . . . . . . Page 3.4 - 5Transmission Air Piping - ZF . . . . . . . . . Page 3.6 - 7

Propeller ShaftDrive shaft . . . . . . . . . . . . . . . . . . . . . . Page 3.8 - 9

Rear AxleInput assembly . . . . . . . . . . . . . . . . . . . Page 3.10 - 11Differential assembly . . . . . . . . . . . . . . . Page 3.12 - 13Axle casing . . . . . . . . . . . . . . . . . . . . . . Page 3.14 - 15Gantry . . . . . . . . . . . . . . . . . . . . . . . . . Page 3.16 - 19Output . . . . . . . . . . . . . . . . . . . . . . . . . Page 3.20 - 23Brake . . . . . . . . . . . . . . . . . . . . . . . . . Page 3.22 - 23

Section 3

PARTS MANUAL


ENVIRO 400

Transmission- Voith Amended:060308

Unit No: GB1516A,B

1/6

VOITH3

RND

5

VOITH4

2

7

11

14

16

1312

15

8

9

17

1819

10


Unit No: GB1516A,B

Transmission- Voith Amended:170811


1 660878 1 Transmission- Voith D854.5E - 4 speed2 660878-3 1 Harness - transmission to harness 0.5m3 660878-1 1 Electronic control unit

660878-2 1 Harness - ECU to transmission 6.0m4 660663 1 Selector - 3 button - “DNR”

660264-1 1 Selector button -“D” Dome Shape660264-2 1 Selector button -“R” Dome Shape660264-3 1 Selector button -“N” Dome Shape650247-12 1 Illumination bulb - selector

5 652061-1 1 Pressure switch - “gearguard”6 660878-4 1 Coupling - Hydrodamp

660878-5 12 Bolt660281-4 12 Washer

7 660878-7 1 Oil filter kit - internal8 660878-8 1 Cover - filter9 660878-9 1 “O” ring - filter cover

10 658866-4 1 Oil cooler11 660878-10 1 Sump gasket12 659927-2 1 Plug - sump13 650247-2 1 Seal - sump plug14 657042-17 1 Gasket - oil cooler elbow15 650002-552 1 Breather cap16 660244-2 1 Hose assembly - oil cooler17 660244-3 1 Hose assembly - oil cooler

425862 1 Bracket - hose support18 652002-184 1 Oil filler cap19 660878-6 1 Dipstick

PARTS MANUAL


ENVIRO 400

Transmission - ZF Amended:060308

Unit No: GB1517A,B

2

3

5

76

4

8

1314 15

1

9

RND


Unit No: GB1517A,B

Transmission - ZF Amended:12/04/14


1 661019 1 Transmission - ZF5HP502C 661019-7 1 Harness - main - 8 plug 661019-8 1 Harness - sub - 5 plug2 660940 1 Electronic control unit - ZF3 660839 1 Selector - 3 button - “DNR”4 652638-1 1 Oil filter kit 5 652638-2 4 Flex plate6 659418-5 10 Screw - flex plate7 656046-122 10 Washer - flex plate screw8 659418-7 2 Capscrew - starter ring to convertor9 656626-6 1 Pressure switch - retarder

659135-3 1 Solenoid valve - accumulator658235-3 1 Speedo sensor659135-4 1 Sump655018-2 1 Gasket - sump653991-2 1 Plug - sump653991-3 1 Washer - sump plug661019-1 A/R Bolt - oil cover bolt-659418-12 1 Temperature Sensor656995-75 1 Seal - temperature sensor

PARTS MANUAL


ENVIRO 400


Unit No: GB1517A,B

21

22

23

241

REAR LOCATION

SOLENOID VALVEFRONT SUSP’N

AU

XIL

IAR

Y &

SU

SP

EN

SIO

N

ZF ACCUMULATOR

412

10mm BLACK

12mm GREEN

12mm GREEN

36

5

GB1515A


Unit No: GB1517A,B



1 654921-1 1 Connector2 654923-2 1 Tee Piece3 654921-4 1 Connector4 654919-2 1 Elbow5 654749 A/R Green - 12 mm O.D.6 654992 A/R Black - 10 mm O.D.

PARTS MANUAL


ENVIRO 400

Drive Shaft Amended:

Unit No: P1510D&E


Unit No: P1510D&E

Drive Shaft Amended:120111


VOITH TRANSMISSION1 659107-2 1 Drive shaft P1510D

10 MFB 112 50D 8 Bolt - transmission & axle653696-1 8 Nut - transmission & axle

659651 1 Grease nipple

659186 2 Kit - drive shaft joint

ZF TRANSMISSION2 659107-2 1 Drive shaft P1510E

10 MFB 112 50D 4 Bolt - axle10 MFN 712P 4 Nut - axle 105 Nm10MCB 112 45 4 Bolt - transmission653696-1 4 Nut - transmission

659186 2 Kit - drive shaft joint

659651 1 Grease nipple

PARTS MANUAL


ENVIRO 400

Drive Axle - Input Amended:

Unit No: AR1511J&K

1

2

3

4

5

6

7

8

9

10

660426-input


Unit No: AR1511J&K

Drive Axle - Input Amended:250906


660426 1 Rear axle - drive - ABS - complete - 6.2:1 AR1511K660426-20 1 Drive head assembly - 6.2:1

660425 1 Rear axle - drive - ABS - complete - 5.74:1 AR1511J 658518-1 1 Drive head assembly - 5.74:1

1a 659922-1 1 Bevel gear set - 6.20:11b 658518-1 1 Bevel gear set - 5.74:1

2 656995-2 1 Bearing3 - A/R4 - A/R5 656995-3 1 Bearing6 656995-4 1 Seal - shaft7 656995-5 1 Dust seal8 656995-6 1 Flange - input9 656995-7 1 Washer

10 656995-8 1 Nut slotted

PARTS MANUAL


ENVIRO 400

Drive Axle - Differential Assembly Amended:

Unit No: AR1511K

1

2

3

3

4

4

6

6

7

7

5

8 210

9

660426-diff

SEE GANTRY DRIVE ITEMS 2 & 3

SEE AXLE CASING ITEMS 5 & 6


Unit No: AR1511K

Drive Axle - Differential Assembly Amended:


1 656995-10 12 Locking screw - crownwheel2 659921-2 1 Differential casing - LH & RH3 656995-12 2 Thrust washer4 656995-13 2 Axle bevel gear5 659921-4 1 Differential spider6 658517-2 4 Diff bevel gear - c/w bush7 659921-3 4 Thrust washer8 656995-17 4 Grooved pin9 656995-18 12 Setscrew - differential casing

10 656995-19 12 Washer

PARTS MANUAL


ENVIRO 400

Drive Axle - Axle Casing Amended:

Unit No: AR1511K

45

6

2

3 7 8 9

4

1011 12

13

11

14

660426-casing

1

15 16


Unit No: AR1511K

Drive Axle - Axle Casing Amended:


Voith/ZF1 659921-5 1 Axle casing - lightweight2 659921-6 1 Stub shaft - short3 659921-7 1 Stub shaft - long4 656995-23 2 “O” ring5 656995-24 1 Bearing6 - A/R Shim7 656995-25 4 Stud8 656995-26 4 Washer9 656995-27 4 Nut

10 659921-9 19/20 Capscrew11 656995-26 35/37 Washer12 659921-8 1 Bracket13 658517-8 1 Drain plug - casing

656995-133 1 “O” ring - drain plug14 656995-34 12/13 Capscrew15 656995-35 1 Type plate16 650795-8 4 Grooved stud

PARTS MANUAL


ENVIRO 400

Drive Axle - Gantry Drive Amended:

Unit No: AR1511K

19

2120

1922

23/24

23

29

3130

28

74 5 6

8

3534

23/24

1415

1615

1718

2526

27

2526

12

9 10 1113

3233

1a,1b


Unit No: AR1511K

Drive Axle - Gantry Drive Amended:


1a 660426-13 1 Gantry housing - LH1b 660426-14 1 Gantry housing - RH

2 656995-38 1 Bearing3 - A/R Shim4 658517-10 1 Cup spring5 656995-39 2 Housing disc6 656995-40 2 Roller cage7 656995-41 2 Plate8 659921-12 1 Input gear9 659921-14 2 Retaining ring

10 659921-15 2 Plate11 659921-16 2 Roller cage12 659921-17 2 Housing disc13 659921-18 2 Cup spring14 - A/R Shim15 659921-19 8 Bearing - idle gear16 656995-45 4 Idler gear17 656995-46 4 ‘O’ ring18 656995-47 4 Idle bearing pin19 656995-48 2 Bearing - output gear20 656995-49 2 Pulse disc21 656995-50 2 Output gear22 - A/R Shim23 660426-1 1 Spring carrier - LH rear & RH front24 660426-2 1 Spring carrier - LH front & RH rear25 656995-53 12 Capscrew26 656995-33 12 Washer

PARTS MANUAL


ENVIRO 400

Drive Axle - Gantry Amended:

Unit No: AR1511K

19

2120

1922

23/24

23

29

3130

28

74 5 6

8

3534

23/24

1415

1615

1718

2526

27

2526

12

9 10 1113

3233

1a,1b


Unit No: AR1511K

Drive Axle - Gantry Amended:


27a 656995-51 1 Console - LH27b 656995-52 1 Console - RH

28 659921-20 1 Breather29 656995-57 4 Setscrew30 656995-132 1 Level plug - gantry 31 656995-133 1 “O” ring - level plug32 656995-125 2 Drain plug - gantry- 33 659921-13 2 “O” ring - drain plug34 658517-13 20 Capscrew35 656995-60 20 Washer

PARTS MANUAL


ENVIRO 400

Drive Axle - Output Amended:

Unit No: AR1511K

1

10

58

9

119

12

13

1615

2

3

45

7

6

1416

660426-output


Unit No: AR1511K

Drive Axle - Output Amended:120111


1 656995-83 2 O ring2 660426-3 2 Hub carrier3 659921-21 2 Screen Sheet4 660426-4 2 Seal - flange shaft5 660426-23 2 Bearing - hub carrier

660426-23 2 Repair kit - c/w bearing6 660426-6 20 Wheel bolt

651043-4 20 Wheel nut - non capped245183-2 20 Cover - wheel nut

7 660426-7 2 Hub8 660426-8 2 Shaft seal9 656995-68 4 Slotted nut

10 656995-69 2 Tab washer11 658517-43 2 ‘O’ ring -shaft seal12 660426-9 2 Flange shaft13 658517-19 20 Screw14 658517-22 12 Capscrew - 70mm lg15 658517-23 20 Capscrew - 115mm lg16 656995-26 32 Washer

Hubodometer AL1527-1659385 1 Hubodometer

PARTS MANUAL


ENVIRO 400

Drive Axle - Brake Amended:

Unit No: AR1511K

5

6

3

2

1

4

660426-brake

7


Unit No: AR1511K

Drive Axle - Brake Amended:


1 658517-26 2 ABS sensor2 660426-15 1 “O” ring - ABS sensor3 660426-16 1 Capscrew4 660426-11 2 Fitted bolt - caliper mounting5 660426-10 10 Screw - caliper mounting6 658517-27 4 Locking nut - actuator7 660426-17 20 Screw


Contents

Braking Amended:270509

Braking System

Used on and up to Chassis No 5115Braking System . . . . . . . . . . . . . . . . . . . . Page 4.2 - 5Pipe Fittings - Braking System . . . . . . . . . Page 4.6 - 9Used on and After Chassis No 5116Braking System - secondary coil . . . . . . . Page 4.10 - 13Pipe Fittings - Braking System . . . . . . . . . Page 4.14 - 17Front Brake Chambers & Rear Brake Actuators Page 4.18 - 19Footbrake Valve and Valve Assembly . . . Page 4.20 - 23Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . Page 4.24 - 25Handbrake Interlock . . . . . . . . . . . . . . . . Page 4.26 - 27Front & Rear Brake Caliper - SB . . . . . . . Page 4.28 - 29Front & Rear Brake Caliper Spares - SB . Page 4.30 - 31Front Brake Caliper - SN . . . . . . . . . . . . . Page 4.32 - 33Front Brake Caliper Spares - SN . . . . . . . Page 4.34 - 35Nylon Brake Tubing Sizes . . . . . . . . . . . . Page 4.36

Section 4

PARTS MANUAL


ENVIRO 400

Braking System Amended:080710

Unit No: FB1522A,C,D,E,F,G,H&J.

211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s

ZF BUS STOP SWITCH ONLY

4

11 12

2221

1

14

22

2

P

S

21

22

COMPRESSOR

PINGTANK

SE

RV

ICE

2

REAR LOCATION

AUXILIARY &SUSPENSION

SERVICE 1

HANDBRAKEINTERLOCKSOLENOID

12

11

12

11

FROM AIR

CLEANER

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY

RETARDER - REFERGEARBOX SECTIONZF ONLY

FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L1

KEY TO PIPE SIZES

16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

AU

XIL

IAR

Y &

SU

SP

EN

SIO

N

SOLENOID VALVEFRONT SUSP’N T

O Z

FA

CC

UM

ULA

TO

R

SAFETYVALVE

37

FRONT KNEEL

FULL KNEEL

OR

TO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR7924 / 8308 / 8510 / 8525 - E400

TO UREA DOSER

26

28

30

2927

30

26

1215

11

14

15

7

32

33

33

35

6

9

15

4

15

29

8

32

23

16

15

31

31

31

31

16 14

16

16

24

25

2

16

18

1

15

13

8

VOITH 36or

ZF 21

22

22

20

10

3

10

17

17

16

16

19

34

18

5a/5b

36

ZF VOITH

20 or 36



Brake System Amended:120111


1 657516 1 Air Dryer (see separate list)656644 1 Silencer

2 430083 1 Pipe assembly - coil424133 1 Bracket - coil653488-6 6 Pipe clip assembly 653489-1 12 Plate - clip assembly - 2 per clip

3 437914 1 Pipe assembly - ping tank to coil443322 1 Plate - hose support SL2171

4 660090 1 Reservoir - ping tank - 1litre426689 1 Mounting bracket - ping tank611005-7 1 Teebolt clip - ping tank

5a 657446-8 1 Hose assembly - compressor to ping tank5b 657446-3 1 Hose assembly - compressor to ping tank - to safety valve tee piece SL2198

6 657493--X 1 Handbrake valve (not serviceable)651787 0.5M Tube - exhaust

7 656249 1 Quadruple circuit protection valve8 659372 2 Relay valve (not serviceable)9 654734 1 Double check valve (not serviceable)

10 658977-A 2 Low pressure switch659154 2 Rubber boot - low presssure switch

11 654979-4 1 Reservoir - Auxiliary & Suspension - 25 litres M2212 654979-11 1 Reservoir - Service 1- 25 litres M2213 654979-9 1 Reservoir - Service 2 - 25 litres M2214 654979-6 2 Reservoir - Auxiliary & Suspension, park - 20 litres M22

656768 A/R Self adhesive rubber - for reservoirs656616-3 2 Teebolt clip - 11 3/4” 656616-2 6 Teebolt clip - 10”656616-1 2 Teebolt clip - 8 3/8”

15 654728 5 Drain valve (not serviceable)16 655026 8 Test point - M1617 656246 2 Test point - M22

PARTS MANUAL


ENVIRO 400



211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

COMPRESSOR

PINGTANK

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

FROM AIR

CLEANER

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L1

KEY TO PIPE SIZES

16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

AU

XIL

IAR

Y &

SU

SP

EN

SIO

N

SOLENOID VALVEFRONT SUSP’N T

O Z

FA

CC

UM

ULA

TO

R

SAFETYVALVE

37

FRONT KNEEL

FULL KNEEL

OR

TO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR7924 / 8308 / 8510 / 8525 - E400

TO UREA DOSER

26

28

30

2927

30

26

1215

11

14

15

7

32

33

33

35

6

9

15

4

15

29

8

32

23

16

15

31

31

31

31

16 14

16

16

24

25

2

16

18

1

15

13

8

VOITH 36or

ZF 21

22

22

20

10

3

10

17

17

16

16

19

34

18

5a/5b

36

ZF VOITH

20 or 36





18 659270 2 Pressure transducer401758 2 Washer - aluminium

19 658019 1 Charge coupling417043 1 Bracket - airline606394 1 Plug and chain

20 652061-1 1 Pressure Switch - “EK” 21 658313 1 Pressure Switch 22 659171 2 Switch - stop lamp

659154 2 Boot - rubber - stop lamp switch23 660687 1 Footbrake valve (see separate list)

656302 4 Silencer24 659387-1 1 Brake chamber - front - LH (see separate list)25 659387-2 1 Brake chamber - front - RH (see separate list)26 655025 2 Hose assembly - Front chamber27 432146 2 Pipe assembly - front chamber - LH

654960 2 Lock nut28 432147 2 Pipe assembly - front chamber - RH

654960 2 Lock nut29 659092 2 Hose assembly - connector to pipe30 657727 2 Hose assembly - valve to connector

657835-1 2 Lock nut31 658879 4 ABS modulating valve32 660314 2 Hose assembly - ABS valve to brake chamber tee

612487 2 Lock nut33 658517-38 1 Brake Actuator - LH & RH (see separate list)34 654733 1 Valve - non return35 655749 1 Hose assembly - tee to D C valve36 441224 1 Pipe assembly - compressor to elbow37 654729-1 1 Safety Valve - (Used on & after Chassis No 4596) SL219838 612747 2 Plug

PARTS MANUAL


ENVIRO 400

Pipe Fittings Amended:271008


211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

COMPRESSOR

PINGTANK

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

FROM AIR

CLEANER

4

L

STRGPILOTVALVE

1

23

PAR

K

L

SOLENOID VALVEFRONT SUSP'N

BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L1

KEY TO PIPE SIZES

16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

AU

XIL

IAR

Y &

S

US

PE

NS

ION


TO Z

F

AC

CU

MU

LATO

R

SAFETYVALVE

FRONT KNEEL

FULL KNEEL

OR

TO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR7924 / 8308 / 8510 / 8525 - E400

TO UREA DOSER

34

34,3824

33,38,41,42

12

35

19

35

9

8,48

42

2

23

5

14

22

28

5

14

8,25

24

24

15

25

17,25,30,38,46

35

13

12

44

29,32

29

16,37,40

5

18

4

47,20 9

28,3628 19

919

199

24

26 23

42

12

19

32

12

12

22

8,48

18,25

8,25

12

8,27

1226

5

44

11

9,19,25

9,19,25

43,46

47

11

81919,25,28

49

3

327,19,9

2319

1

6

27,32,52

4,19,27,52,

37

36

36





1 654920-4 - Elbow2 660930 - Elbow3 654931 - Adaptor4 654919-3 - Elbow5 654919-4 - Elbow6 654919-6 - Elbow7 657240 - Elbow8 654919-2 - Elbow9 654919-3 - Elbow

10 661729* - Elbow - 45 (658017)11 654919-7 - Elbow12 654919-8 - Elbow13 661727* - Elbow (654925)14 654933-4 - Elbow15 656489 - Bulkhead connector16 654912 - Bulkhead connector17 654921-6 - Connector18 654921-2 - Connector19 654921-4 - Connector20 654921-5 - Connector21 654921-13 - Connector22 654909-7 - Connector23 654921-7 - Connector24 661726* - Tee piece (654923-1)25 661725* - Tee piece (654923-2)26 661724* - Tee piece (654923-3)27 654922 Tee piece - bracketed28 661722* - Tee piece (654924)29 661721* Tee piece (655017)

PARTS MANUAL


ENVIRO 400



211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

COMPRESSOR

PINGTANK

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

FROM AIR

CLEANER

4

L

STRGPILOTVALVE

1

23

PAR

K

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L1

KEY TO PIPE SIZES

16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

AU

XIL

IAR

Y &

S

US

PE

NS

ION


TO Z

F

AC

CU

MU

LATO

R

SAFETYVALVE

FRONT KNEEL

FULL KNEEL

OR

TO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR7924 / 8308 / 8510 / 8525 - E400

TO UREA DOSER

34

34,3824

33,38,41,42

12

35

19

35

9

8,48

42

2

23

5

14

22

28

5

14

8,25

24

24

15

25

17,25,30,38,46

35

13

12

44

29,32

29

16,37,40

5

18

4

47,20 9

28,3628 19

919

199

24

26 23

42

12

19

32

12

12

22

8,48

18,25

8,25

12

8,27

1226

5

44

11

9,19,25

9,19,25

43,46

47

11

81919,25,28

49

3

327,19,9

2319

1

6

27,32,52

4,19,27,52,

37

36

36





30 654927-2 - Reducer32 657950-1 - Reducer33 654927-2 - Reducer34 654927-7 - Reducer35 654910 - Plug36 612747 - Plug37 606394 - Plug38 655003 - Washer - seal39 401758 - Washer - seal40 653148 - Ring41 654938 - Adaptor42 418461 - Adaptor43 652929 - Seal - bonded44 654909-10 - Adaptor45 654909-3 - Adaptor46 654909-8 - Adaptor47 424528 - Connector48 612487 - Nut49 660908-1 - Elbow50 661410-1 - Tee piece - swivel SL219851 661406 - Adaptor SL219852 654921-9 - Connector

NOTE* CERTAIN PIPE FITTING HAVE BEEN SUPERSEDED IN DESIGN. IFA REPLACEMENT FITTING IS REQUIRED, IF ONE OF THEADJACENT FITTINGS IS MARKED WITH A * THEN THIS FITTINGNEEDS TO BE REPLACED AS WELL DUE TO DIMENSIONALCHANGES IN FITTING DESIGN.

PARTS MANUAL


ENVIRO 400


Unit No: FB1526C&D

211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L

1

KEY TO PIPE SIZES

AU

XILI

ARY

&SU

SPEN

SIO

N


16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

TO Z

FA

CC

UM

ULA

TOR

FRONT KNEEL

FULL KNEEL

ORTO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR 8525 - E400

TO UREA DOSER

COMPRESSOR

FROM AIR

CLEANER

SAFETYVALVE

PINGTANK

26

28

30

2927

30

26

1215

11

14

15

7

32

33

33

35

6

9

154

15

29

8

32

23

16

15

31

31

31

31

16

14

16

16

24

25

2

16

18

1

15

13

8

VOITH 36or

ZF 21

22

22

20

10

10

17

17

16

16

19

34

18

5

ZF VOITH

20 or 36

39a/39b

3

40


Unit No: FB1526C&D



1 657516 1 Air Dryer (see separate list)656644 1 Silencer

2 430083 1 Pipe assembly - coil424133 1 Bracket - coil653488-6 6 Pipe clip assembly 653489-1 12 Plate - clip assembly - 2 per clip

3 446336 1 Pipe assembly - compressor to ping tank4 660090 1 Reservoir - ping tank - 1litre

446330 1 Mounting bracket - ping tank611005-7 1 Teebolt clip - ping tank

5 657446-3 1 Hose assembly - compressor to ping tank - to safety valve tee piece6 657493--X 1 Handbrake valve (not serviceable)

651787 0.5M Tube - exhaust7 656249 1 Quadruple circuit protection valve8 659372 2 Relay valve (not serviceable)9 654734 1 Double check valve (not serviceable)

10 658977-A 2 Low pressure switch659154 2 Rubber boot - low presssure switch

11 654979-4 1 Reservoir - Auxiliary & Suspension - 25 litres M2212 654979-11 1 Reservoir - Service 1- 25 litres M2213 654979-9 1 Reservoir - Service 2 - 25 litres M2214 654979-6 2 Reservoir - Auxiliary & Suspension, park - 20 litres M22

656768 A/R Self adhesive rubber - for reservoirs656616-3 2 Teebolt clip - 11 3/4” 656616-2 6 Teebolt clip - 10”656616-1 2 Teebolt clip - 8 3/8”

15 654728 5 Drain valve (not serviceable)16 655026 8 Test point - M16

PARTS MANUAL


ENVIRO 400


Unit No: FB1526C&D

211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L

1

KEY TO PIPE SIZES

AU

XILI

ARY

&SU

SPEN

SIO

N


16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

TO Z

FA

CC

UM

ULA

TOR

FRONT KNEEL

FULL KNEEL

ORTO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR 8525 - E400

TO UREA DOSER

COMPRESSOR

FROM AIR

CLEANER

SAFETYVALVE

PINGTANK

26

28

30

2927

30

26

1215

11

14

15

7

32

33

33

35

6

9

154

15

29

8

32

23

16

15

31

31

31

31

16

14

16

16

24

25

2

16

18

1

15

13

8

VOITH 36or

ZF 21

22

22

20

10

10

17

17

16

16

19

34

18

5

ZF VOITH

20 or 36

39a/39b

3

40


Unit No: FB1526C&D



16 655026 8 Test point - M1617 656246 2 Test point - M2218 659270 2 Pressure transducer

401758 2 Washer - aluminium19 658019 1 Charge coupling

417043 1 Bracket - airline606394 1 Plug and chain

20 652061-1 1 Pressure Switch - “EK” 21 658313 1 Pressure Switch 22 659171 2 Switch - stop lamp

659154 2 Boot - rubber - stop lamp switch23 660687 1 Footbrake valve (see separate list)

656302 4 Silencer24 659387-1 1 Brake chamber - front - LH (see separate list)25 659387-2 1 Brake chamber - front - RH (see separate list)26 655025 2 Hose assembly - Front chamber27 432146 2 Pipe assembly - front chamber - LH

654960 2 Lock nut28 432147 2 Pipe assembly - front chamber - RH

654960 2 Lock nut29 659092 2 Hose assembly - connector to pipe30 657727 2 Hose assembly - valve to connector

657835-1 2 Lock nut31 658879 4 ABS modulating valve32 660314 2 Hose assembly - ABS valve to brake chamber tee

612847 2 Lock nut

PARTS MANUAL


ENVIRO 400


Unit No: FB1526C&D

211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L

1

KEY TO PIPE SIZES

AU

XILI

ARY

&SU

SPEN

SIO

N


16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

TO Z

FA

CC

UM

ULA

TOR

FRONT KNEEL

FULL KNEEL

ORTO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR 8525 - E400

TO UREA DOSER

COMPRESSOR

FROM AIR

CLEANER

SAFETYVALVE

PINGTANK

26

28

30

2927

30

26

1215

11

14

15

7

32

33

33

35

6

9

154

15

29

8

32

23

16

15

31

31

31

31

16

14

16

16

24

25

2

16

18

1

15

13

8

VOITH 36or

ZF 21

22

22

20

10

10

17

17

16

16

19

34

18

5

ZF VOITH

20 or 36

39a/39b

3

40


Unit No: FB1526C&D



33 658517-38 1 Brake Actuator - LH & RH (see separate list)34 654733 1 Valve - non return35 655749 1 Hose assembly - tee to D C valve36 446341 1 Pipe assembly - coil to coil37 654729-1 1 Safety Valve 38 612747 2 Plug

39a 446333 1 Coil assembly - ZF transmission446342 1 Bracket cooling coil - ZF446343 1 Bracket cooling coil (slotted angle)

39b 446396 1 Coil assembly - Voith transmission446398 1 Bracket cooling coil - Voith446343 1 Bracket cooling coil (slotted angle)

40 446341 1 Pipe assembly - coil to pipe

Service List kits are available for conversion to second cooling coils:SL2236 - Compressor cooling coil - ZF variant

SL2264 - Compressor cooling coil - Voith variant REF: D24668

PARTS MANUAL


ENVIRO 400


Unit No: FB1526C&D

211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L

1

KEY TO PIPE SIZES

AU

XILI

ARY

&SU

SPEN

SIO

N


16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

TO Z

FA

CC

UM

ULA

TOR

FRONT KNEEL

FULL KNEEL

ORTO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR 8525 - E400

TO UREA DOSER

COMPRESSOR

FROM AIR

CLEANER

SAFETYVALVE

PINGTANK

34

34,3824

33,38,41,42

12

35

19

35

9

8,48

42

2

23

5

14

22

28

5

14

8,25

24

24

15

25

17,25,30,38,46

35

12

29,32

29

16,37,40

5

4

47,20 9

28,3628 19

919

199

24

26 23

42

12

19

32

12

12

22

8,48

18,25

8,25

12

8,27

12

26

5

44

11

9,19,25

91925

46

4347

11

81919,25,28

49

3

327,19,9

2319

1

6

27,32,52

4,19,27,52,

5051

53

15


Unit No: FB1526C&D



1 654920-4 - Elbow2 660930 - Elbow3 654931 - Adaptor4 654919-3 - Elbow5 654919-4 - Elbow6 654919-6 - Elbow7 657240 - Elbow8 654919-2 - Elbow9 654919-3 - Elbow

10 661729 - Elbow - 45°11 654919-7 - Elbow12 654919-8 - Elbow13 661727 - Elbow14 654933-4 - Elbow15 656489 - Bulkhead connector16 654912 - Bulkhead connector17 654921-6 - Connector18 654921-2 - Connector19 654921-4 - Connector20 654921-5 - Connector21 654921-13 - Connector22 654909-7 - Connector23 654921-7 - Connector24 661726 - Tee piece25 661725 - Tee piece26 661724 - Tee piece27 654922 Tee piece - bracketed28 661722 - Tee piece29 661721 Tee piece

PARTS MANUAL


ENVIRO 400


Unit No: FB1526C&D

211

124

2

FRONT AXLEREAR AXLE

13 23

2

13

EK

121

21

22

23

24

1

s


4

11 12

2221

1

14

22

2

P

S

21

22

SE

RV

ICE

2

REAR LOCATION


SERVICE 1


12

11

12

11

4

L

STRGPILOTVALVE

1

23

PA

RK

L


BODYBUILDERSUPPLY


FRONT LOCATION

CHARGECOUPLING

REAR LOCATION

L

1

KEY TO PIPE SIZES

AU

XILI

ARY

&SU

SPEN

SIO

N


16mm Red

12mm Red

10mm Red

12mm Orange

10mm Orange

6 mm Orange

6mm Yellow

10mm Yellow

12mm Yellow

12mm Green

4mm Black

TO Z

FA

CC

UM

ULA

TOR

FRONT KNEEL

FULL KNEEL

ORTO UREA DOSER

TO UREA DOSER

21


TO ZFACCUMULATOR

11,26,21

11819

25,19,4

EARLIER MODELS

AR 8525 - E400

TO UREA DOSER

COMPRESSOR

FROM AIR

CLEANER

SAFETYVALVE

PINGTANK

34

34,3824

33,38,41,42

12

35

19

35

9

8,48

42

2

23

5

14

22

28

5

14

8,25

24

24

15

25

17,25,30,38,46

35

12

29,32

29

16,37,40

5

4

47,20 9

28,3628 19

919

199

24

26 23

42

12

19

32

12

12

22

8,48

18,25

8,25

12

8,27

12

26

5

44

11

9,19,25

91925

46

4347

11

81919,25,28

49

3

327,19,9

2319

1

6

27,32,52

4,19,27,52,

5051

53

15


Unit No: FB1526C&D



30 654927-2 - Reducer32 657950-1 - Reducer33 654927-2 - Reducer34 654927-7 - Reducer35 654910 - Plug36 612747 - Plug37 606394 - Plug38 655003 - Washer - seal39 401758 - Washer - seal40 653148 - Ring41 654938 - Adaptor42 418461 - Adaptor43 652929 - Seal - bonded44 654909-10 - Adaptor45 654909-3 - Adaptor46 654909-8 - Adaptor47 424528 - Connector48 612487 - Nut49 660908-1 - Elbow50 661410-1 - Tee piece - swivel SL219851 661406 - Adaptor SL219852 654921-9 - Connector53 661974 - Elbow - 45°

12 11 24/2

4

1/2

PARTS MANUAL


ENVIRO 400

Front Brake Chambers & Rear Brake Actuators Amended:

Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D

2

1

FRONT BRAKE CHAMBER REAR ACTUATOR


Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D

Front Brake Chambers & Rear Brake Actuators Amended:


FRONT BRAKE CHAMBER - Type 221a 659387-1 1 Brake chamber - LH1b 659387-2 1 Brake chamber - RH

2 659387-8 2 Diaphragm - T22

REAR BRAKE ACTUATOR1 658517-38 2 Brake actuator2 658470-44 2 Diaphragm

PARTS MANUAL


ENVIRO 400

Footbrake Valve Amended:050609

Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D - 660687

659171658313656626-6ZF - "EK"

652061-1VOITH

"GEARGUARD"


Unit No: FB1522A,C,D,E,F,G,H&J. FB1526D - 660687

Valve Assembly Amended:


660687 1 Footbrake valve complete 651847-25 1 Repair kit - valve (see separate list)659776-2 1 Repair kit - treadle (*Comprising items: 13, 21, 22, 23,24, 26)

1 660687-1 1 Brake valve assembly2 - 1 Tappet3 658719-10 2 ‘O’ ring4 - 1 Body5 660687-2 1 Switch6 658719-11 1 Gasket/Seal7 - 2 Washer8 - 6 Screw M4x129 - 1 Cover

10 - 4 Stud11 - 4 Nut M812 - 1 Base13 1 Pin*14 - 1 Compression spring15 - 1 Nut M816 - 1 Bolt M8x2817 658719-3 1 Bush18 658719-13 1 Ring19 - 1 Pin20 - 1 Operating roller21 - 1 Lock washer*22 - 1 Pressure plate*23 - 1 Pressure plate*24 - 1 Spacer*25 658719-8 1 Treadle26 - 1 Hollow rivet 3.2 x 10*27 658719-9 1 Pedal cover

PARTS MANUAL


ENVIRO 400

Footbrake Valve Amended:


*

*



Valve Assembly Amended:


651847-25 1 Repair kit - (comprising items marked *)

1 658719-17 1 Body2 - 1 ‘O’ ring* 71.12 x 2.623 658719-15 2 Valve*4 - 2 Conical spring*5 - 2 Spacer6 - 2 ‘O’ ring* 25.07 x 2.627 - 2 ‘O’ ring* 32.0 x 2.58 - 1 C-Clip9 - 1 ‘O’ ring* 15.55 x 2.62

10 - 1 Piston11 - 1 Tappet12 - 1 Compression spring13 - 1 Applicator14 - 2 ‘O’ ring* 63.1 x 3.53

- 2 ‘O’ ring* 64.0 x 3.015 - 1 Lower body16 - 4 Bolt M6 x 5517 658719-16 1 ‘O’ ring* 40.95 x 2.6218 658719-18 1 Venting guide19 - 1 C-Clip20 - 1 Compression spring21 - 1 ‘O’ ring* 50.4 x 3.5322 - 2 Ring*23 658719-19 1 Piston24 - 1 Spacer25 - 1 Boot*26 - 1 C-Clip

PARTS MANUAL


ENVIRO 400

Air Dryer Amended:


1

2

3

4

5

6

7

8

9

10

1311

1214

15

16

17

23

26

27

2220

18

21

19

28

657516


Unit No: FB1522A,C,D,E,F,G,H&J. FB1526C&D- 657516

Air Dryer Amended:130906


657516 Air dryer unit - complete

1 - 25 657516-1 1 Repair kit26 658208-2 1 Heater plug27 658208-3 1 Filter cartridge

657516-2 1 Silencer assembly657186-6 A/R Lubricant

PARTS MANUAL


ENVIRO 400

Handbrake Interlock Amended:

Unit No: AL1511-2

4mm

BLUE 2

AR7828

8

AR7573

1,3,4

5,6,7

10

3

1

2

SUPPLY FROMAUXILIARY &SUSPENSIONRESERVOIR

HANDBRAKEVALVE

6 m

m

OR

AN

GE

6 m

m

OR

AN

GE

6 mm

ORANGE6 mm

ORANGE

31

2

21

1

SOLENOIDVALVE

FROM RELAYVALVE SIGNAL

LINE - Port 4

EXHAUST

EXHAUST

PILOTVALVE

4 mm

BLACK

4 mm

BLACK

STEERINGCOLUMN

6 mm

ORANGE

21


LINE - Port 1

2

31PILOT VALVE OPERATION

12


Unit No: AL1511-2

Handbrake Interlock Amended:


1 655776 1 Solenoid Valve2 652285 1 Connector - kostal3 MCB-108-55P 2 Bolt - M8 x 554 MCN-708P 2 Nut - full nyloc M85 654339 1 Nut - 6mm-M12 x 1.56 654340 1 Olive - 6mm7 655832-2 1 Sleeve - 6mm od x 4mm id8 654919-5 1 Connector elbow 90 deg9 654921-8 1 Connector straight

10 654748 0.1m Pipe nylon - 6mm orange

For details of Steering Column Adjustment see Page 7.9

PARTS MANUAL


ENVIRO 400

Front & Rear Brake Caliper - SB type Amended:

Unit No: AF1511

Assembly grease (white)

Assembly grease (white)

pre-applied adhesive

REAR

FRONT

THIS ILLUSTRATION SHOWS THE REAR CALIPER. FRONT CALIPER

COMPONENT LAYOUT IS THE SAME ONLY THE ORIENTATION OF THE CALIPER IS DIFFERENT ON THE

FRONT CALIPER.

F659332/R659334


Unit No: AF1511

Front & Rear Brake Caliper - SB type Amended:271008


660364-9 1 Front caliper RH - rationalised. SN type

660364-10 1 Front caliper LH - rationalised. SN type

660426-24 1 Rear caliper RH - rationalised. SB type

660426-25 1 Rear caliper LH - rationalised. SB type

PLEASE NOTE : Rationalised calipers are supplied without pads,carriers or wear indicators. Spares kits for these are on Page 4.23

• The SN units are designed to be interchangeable with the replaced SB units and so there should be no installation issues whenreplacing SB disc brakes with the correct SN unit. The output (clamping force and brake torque) is the same for both SB and SN discbrakes. mixing of SB and SN units on the same axle is permitted.• The same Rationalised Caliper is offered for both SB and SN Air Disc Brakes (the Rationalised Caliper offered for the SB disc brakeshas been of the SN design for some time) and it can be mounted on either Carrier.• The Brake Pad Set and Wear Indicator Kit used in the SB disc brakes can be used in the SN units.• The Guide Pins and Bushes Kit and Tappet and Boot Kit for the SN disc brakes are different and some new tools are required forservicing the SN type.• The SN range of Air Disc Brakes covers only the ‘axial’ type and so the Air Disc Brakes on the Enviro 400 rear axles remainunchanged (they are the ‘radial’ type). (Y061650-EN-000)

NOTE : If Spares are required for the original fitment caliper, thecaliper number needs to be noted to determine weather it is an SBor SN caliper.This is can be read off the caliper Identification plate located as shown.

PARTS MANUAL


ENVIRO 400

Front & Rear Brake Caliper Spares - SB type Amended:120907

Unit No: AF1511

11109

1 3 4

5 6 7

8

2


Unit No: AF1511

Front & Rear Brake Caliper Spares - SB type Amended:120907


1 658470-41 1 Brake pad kit (axle set) 2 659956 1 Brake pad kit c/w wear sensor (axle set)

3a 659387-13 2 Brake carrier - front3b 660426-18 2 Brake carrier - rear - LH3c 660426-19 2 Brake carrier - rear -RH4 659332-5 2 Ceramic Tappet - with boot 5 659921-29 2 Steel cap kit6 659921-28 2 Adjuster cap kit 7 659334-2 2 Guide pin and seal kit

8a 658470-39 2 Disc - front brake8b 657303-126 2 Disc - rear brake

9 659334-8 1 Wear indicator kit - with cable (axle set) 10 659334-7 1 Wear indicator kit - no cable (axle set)11 659332-4 1 Caliper overhaul toolkit

657303-139 A/R Assembly grease - coloured657303-140 A/R Assembly grease - white

PARTS MANUAL


ENVIRO 400

Front Brake Caliper- SN type Amended:120907

Unit No: AF1411

pre-applied adhesive

White assembly grease


Unit No: AF1411

Front Brake Caliper- SN type Amended:271008


660364-9 1 Front caliper RH - rationalised. SN type

660364-10 1 Front caliper LH - rationalised. SN type

PLEASE NOTE : Rationalised calipers are supplied without pads,carriers or wear indicators. Spares kits for these are on Page 4.27

• The SN units are designed to be interchangeable with the replaced SB units and so there should be no installation issues whenreplacing SB disc brakes with the correct SN unit. The output (clamping force and brake torque) is the same for both SB and SN discbrakes. mixing of SB and SN units on the same axle is permitted.• The same Rationalised Caliper is offered for both SB and SN Air Disc Brakes (the Rationalised Caliper offered for the SB disc brakeshas been of the SN design for some time) and it can be mounted on either Carrier.• The Brake Pad Set and Wear Indicator Kit used in the SB disc brakes can be used in the SN units.• The Guide Pins and Bushes Kit and Tappet and Boot Kit for the SN disc brakes are different and some new tools are required forservicing the SN type.• The SN range of Air Disc Brakes covers only the ‘axial’ type and so the Air Disc Brakes on the Enviro 400 rear axles remainunchanged (they are the ‘radial’ type). (Y061650-EN-000)

NOTE : If Spares are required for the original fitment caliper, thecaliper number needs to be noted to determine weather it is an SBor SN caliper.This is can be read off the caliper Identification plate located as shown.

PARTS MANUAL


ENVIRO 400

Front Brake Caliper Spares - SN type Amended:080708

Unit No: AF1411

1 3 4

5 7

2

8 9 10


Unit No: AF1411

Front Brake Caliper Spares - SN type Amended:271008


1 660364-7 1 Brake pad kit (axle set) 2 660364-5 2 Brake carrier - front3 660364-3 2 Ceramic Tappet - with boot 4 660364-6 2 Steel cap kit5 660364-8 2 Adjuster cap kit 6 660364-4 2 Guide pin and seal kit7 658470-39 2 Disc - front brake8 659334-8 1 Wear indicator kit - with cable (axle set) 9 659334-7 1 Wear indicator kit - no cable (axle set)

10 660364-11 1 SN Caliper overhaul toolkit

657303-139 A/R Assembly grease - coloured657303-140 A/R Assembly grease - white

PARTS MANUAL


ENVIRO 400

Unit No:

Nylon Brake Tubing (metric) Amended:


Nylon Brake Tubing654991 a/r Red - 10 mm O.D. Air Feed Circuit654746 a/r Red - 12 mm O.D.654745 a/r Red - 16 mm O.D.

654744 a/r Yellow - 6 mm O.D. Service Brake656416 a/r Yellow - 10 mm O.D.654743 a/r Yellow - 12 mm O.D.

654750 a/r Green - 6 mm O.D. Auxiliary Equipment656415 a/r Green - 10 mm O.D.654749 a/r Green - 12 mm O.D.

654748 a/r Orange - 6 mm O.D Handbrake Circuit656417 a/r Orange - 10 mm O.D.654747 a/r Orange - 12 mm O.D

655022 a/r Black - 4 mm O.D. Gauge lines654994 a/r Black - 6 mm O.D. Signal lines654992 a/r Black - 10 mm O.D. Exhaust brake654993 a/r Black - 12 mm O.D. Signal lines

Inline Connector (repair)655416-8 A/R Inline connector - Ø6mm655416-1 A/R Inline connector - Ø8mm655416-2 A/R Inline connector - Ø10mm655416-3 A/R Inline connector - Ø12mm

610224 1 Brake Tubing Cutter


Contents

Electrical System and Instrumentation Amended:

Used on & up to Chassis No 5114 excluding 4625 & 4752Electrical System

Instrument binnacle assembly . . . . . . . . Page 5.2 - 5Front Electrical Distribution Centre - EDC Page 5.6 - 7PCB assembly - Front EDC . . . . . . . . . . Page 5.8 - 9Rear Electrical Distribution Centre - EDC Page 5.10 - 11PCB assembly - Rear EDC . . . . . . . . . . Page 5.12 - 13Cables . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.14 - 15Used on and up to Chassis No 4306Harnesses - Euro 4 . . . . . . . . . . . . . . . . Page 5.16Used on and after Chassis No 4307Harnesses - Euro 4+ . . . . . . . . . . . . . . . Page 5. 17Micellaneous . . . . . . . . . . . . . . . . . . . . . Page 5.18 - 19

Battery CarrierBattery Carrier . . . . . . . . . . . . . . . . . . . . Page 5.20 - 23Battery Boost Socket . . . . . . . . . . . . . . . Page 5.23Battery Carrier Area . . . . . . . . . . . . . . . . Page 5.24 - 25

Used on & after Chassis No 4625, 4752, 5115 onwardsElectrical System

Instrument binnacle assembly . . . . . . . . Page 5.26 - 27Front Electrical Distribution Centre - EDC Page 5.28 - 29PCB assembly - Front EDC . . . . . . . . . . Page 5.30 - 31Rear Electrical Distribution Centre - EDC Page 5.32 - 33PCB assembly - Rear EDC . . . . . . . . . . Page 5.34 - 35Cables . . . . . . . . . . . . . . . . . . . . . . . . . Page 5.36Harnesses . . . . . . . . . . . . . . . . . . . . . . Page 5.37

Battery CarrierBattery Carrier Area . . . . . . . . . . . . . . . . Page 5.38 - 39

Section 5

PARTS MANUALENVIRO 400

Electrical System - Instrument Binnacle Amended:100907

Unit No: E1519A,B,C,D,E,F&G

3

6

4

5

2

1a

STOP

WAIT�TO�

START

miles

mph

kmh

9 8

8

1011131415

16a 18

17a/17b 12

7Front

Rear 439053-1/443153-1

191415

16b

1b






Used on Chassis No 3926 & 3941439053-6 1 Binnacle assembly - membrane panel - Speedometer S1513B

Used from and up to Chassis No 3962 - 4294441920-1 1 Binnacle assembly - membrane panel - Speedometer - LH column switch OL1537-1

Used on and after Chassis No 4295443153-1 1 Binnacle assembly - membrane panel - Speedometer S1514A443153-5 1 Binnacle assembly - membrane panel - Tachograph TG1514B443173-5 1 Binnacle assembly - membrane panel - Speedometer - LH column switch OL1537-1

INSTRUMENT BINNACLE - 2 HOLE ROCKER SWITCH PANEL1a 660909-4 1 Binnacle front panel - 2 hole rocker switch

2 660909-5 1 Bracket support internal660909-13 0.3m Grommet strip

3 660909-1 1 Binnacle rear4 660909-6 1 Bracket support external

MCS 3606 45P 4 Bolt 5 431936 1 Clamping plate

6a 660909-2 1 Front shroud cover7b 660909-3 1 Rear shroud cover6a 436510 1 Front shroud cover- LH indicator stalk OL1537-17b 436509 1 Rear shroud cover- LH indicator stalk OL1537-1

8 660696 1 Membrane panel assembly439056 1 Switch insert legends - one set

9a 658837 1 Lever switch - ignition Option660909-10 1 Decal, ignition switch658842 1 Switching element660246 1 Ring - anti twist

9b 659923 1 Key switch actuator Option76500215 1 Security key - Alexander lock

PARTS MANUAL


ENVIRO 400



3

6

4

5

2

1a

STOP

WAIT�TO�

START

miles

mph

kmh

9 8

8

1011131415

16a 18

17a/17b 12

7Front

Rear 439053-1/443153-1

191415

16b

1b



Electrical System Amended:120111


10a 660912 1 Speedometer S1514A660912-1 1 Bulb 658178-2 1 Holder - bulb

10b 661083 1 Tachograph S1514B11 660909-8 1 Warning lamp housing12 660909-9 1 Warning light decal strip - ISO

660909-7 1 Warning light PCB660909-12 1 Gasket, warning light housing to panel

13 661828 1 Screen Control Unit (SCU)660909-11 1 Gasket, SCU

14 658825 1 Rocker switch - hazard lights15 658840 1 Rocker switch - master16a 269558 1 Rotary switch assembly - headlights / cab lights

655321 1 Switch653757 1 Bulb

17a 660909-14 1 Harness - binnacle - 2 hole rocker switch18 660909-15 1 Cable - detail ribbon

INSTRUMENT BINNACLE - 3 HOLE ROCKER SWITCH PANELUsed on and up to 5114 Chassis No 4295 excluding 4625 & 4752All other parts as above

1b 661345-1 1 Binnacle front panel - 3 hole rocker switch16b 661349 1 Switch - lighting

661348 1 Label - lighting switch surround661350 1 Switching element

17b 661345-2 1 Harness - binnacle - 3 hole rocker switch19 661346 1 Rocker switch - drivers cab lights

660909-16 1 Low air buzzer1 SL2157 1 Buzzer - upgrade kit

PARTS MANUAL


ENVIRO 400

Electrical System - Front - EDC Amended:


KNORR - BREMSE

BLINKCODE

RETARDON/OFF

ENG DIAGON/OFF

439898-FRT

CA

MU

�IO

U�

IOU

�

8

9

3 4 5 6

12

7

13

8

11

1

2

2

10

10


Electrical System - Front - EDC Amended:120111


1 659973 1 Control unit - CAMU609009-12 4 Spacer

2 659972 2 Control unit - IOU609009-12 2 Spacer

3 660077 1 Switch - “Engine diagnostics” - Green4 657879 1 Switch - “Blink code” - Yellow5 660168 1 Switch - “Retarder” - Green

6a 657878 1 Housing - switch - centre6b 657877 2 Housing - switch - end

7 426290 1 Bracket - diagnostic switches8 660811 1 ABS ‘E’ control unit

662093 1 Harness - adaptor - ABS-D TO ABS-E (Needed if replacing ABS-D ECU) SL23159 439617 1 PCB assembly - front EDC (See separate list)

10 438003-3 2 Trunking - 25mm - 235mm lg11 438003-7 2 Trunking - 25mm - 190mm lg12 438004-1 1 Trunking - 50mm - 540mm lg13 439900 1 Bracket - diagnostic socket

440801 1 Label - FEDC - 441454 1 Label - FEDC - Identic filler vehicles441115 1 Label - FEDC - ZF Transmission

Used on & after Chassis No 4295 to 4302 & 4306 onwards443306 1 Label - FEDC - ZF Transmission 440797 1 Harness - front EDC


PARTS MANUAL


ENVIRO 400

Electrical System - PCB - Front - EDC Amended:180209


20 30 3040 35 25

F1

2

F1

3

F1

4

F1

5

F1

6

F1

7

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

F1

F2

F3

F4

F5

F29

F30

F31

F32

F33

F34

F6

F7

F8

F9

F10

F11

R1

R2

torq

ue

3,9

Nm

BA

TT

+3

0

torq

ue

17

Nm

GN

D3

1torq

ue

3,9

Nm

SW

BA

TT

+3

0A

Ign

itio

n

AL

EX

AN

DE

R-D

EN

NIS

PC

B -

FR

ON

T -

ED

CP

T.

NO

43

96

17

8 10 12 10 11 9

13

1,14

10

439617

3A

10A

15A

20A

2

3

6

7

8

5A

47.5A

5


Unit No: 439617

Electrical System - PCB - Front - EDC Amended:180209


Used on & up to Chassis No 5114 excluding 4625 & 4752439617 1 PCB assembly - front EDC

1 439610 1 PCB board2 651598-2 A/R Add-A-Fuse - 3 Amp - Violet3 651598-4 A/R Add-A-Fuse - 5 Amp - Tan4 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown5 651598-6 A/R Add-A-Fuse - 10 Amp - Red6 651598-7 A/R Add-A-Fuse - 15 Amp - Blue7 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow8 656674 1 Fuse - “maxi” - 20 Amp - Yellow9 660060 1 Fuse - “maxi” - 25 Amp - Grey

10 656548 2 Fuse - “maxi” - 30 Amp - Green11 660061 1 Fuse - “maxi” - 35 Amp 12 657794 1 Fuse - “maxi” - 40 Amp - Orange13 657023 1 Relay - ignition14 660721 4 Stand off assembly - c/w screws

PARTS MANUAL


ENVIRO 400

Electrical System - Rear - EDC Amended:


IOU

3

IOU

4

IOU

5R

ETA

RD

O

N/O

FF

IOU

IOU

IOU

1 1 2a/2b

13 467

8

4407859 105



Electrical System - Rear - EDC Amended:120111


Used on & up to Chassis No 5114 excluding 4625 & 47521 659972 3 Control unit - IOU

609009-12 12 Spacer657585 1 Connector - power - IOU662227 A/R Terminal - power connector X220

2a 660878 1 Electronic control unit - Voith transmission2b 660940 1 Electronic control unit - ZF transmission3 657799 1 Switch - “hand throttle” - Green4 426897 1 Bracket - switch5 76752365 1 Dual Channel Current Monitor 6 655933 1 Relay - starter7 439616 1 PCB assembly - rear EDC (See separate list)8 438004-2 1 Trunking - 50mm - 700 mm lg9 438004-1 1 Trunking - 50mm - 540mm lg10 3451153NO1 1 Mounting bracket - REDC

443307 1 Label - REDC

PARTS MANUAL


ENVIRO 400

Electrical System - PCB - Rear - EDC Amended:240107

Unit No: 439616

3

102

2 2

2

4

5

6

7

30

30

F24SPARE

30

30

F23

30

30

F4

30

30

F3

30

30

F2

30

30

F1

5

3

15

15

5

7.5

20

3

20

5

20

20

20

10

5

10

5

20

torque

3,9Nm

BATT+

30

torque

17 Nm

GND

31

torque

9Nm

SW

BATT+

30A

Coolant

Module - Lower

Coolant

Module - Upper

Fuel Heater

F14

F15

F16

F19

F20

F21

F10

F11

F12

F13

F17

F18

F22

F5

F6

F7

F8

F9

IGNITION

ALEXANDER-DENNIS

PCB - REAR- EDC

PT. NO 439609


Unit No: 439616

Electrical System - PCB - Rear - EDC Amended:21.12.06


Used on & up to Chassis No 5114 excluding 4625 & 4752439616 1 PCB assembly - Rear EDC

1 439609 1 PCB board2a 651598-2 A/R Add-A-Fuse - 3 Amp - Violet2b 651598-4 A/R Add-A-Fuse - 5 Amp - Tan2c 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown2d 651598-6 A/R Add-A-Fuse - 10 Amp - Red2e 651598-7 A/R Add-A-Fuse - 15 Amp - Blue2f 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow3 656548 6 Fuse - “maxi” - 30 Amp - Green4 437840 1 Coolant module 5 651438 1 Relay6 657023 1 Relay7 660721 4 Stand off assembly - c/w screws

PARTS MANUAL


ENVIRO 400

Electrical System - Cables Amended:100407


150A

THIS IS A SCHEMATIC DIAGRAM ONLY FOR CABLE IDENTIFICATION ONLY AND SHOULD NOT BE USED AS A WIRING DIAGRAM

ALT

STA

RT

ER

ENGINE

FEDC

125A

++

--

BATT+30

GND31 SW

BATT+30A

REDC

40A

40AMASTERSWITCH

175A

MIDI

MIDI

MEGA

BATT+30

GND31

SWBATT+

30A

13

US

ED

ON

AN

D A

FT

ER

CH

AS

SIS

NO

416

2

40AMIDI

1

5

4

11

3

2

7

6

9

10

15 14

12

17

18

21

20

19

7

8

16

7b22

8b

-

+

23



Electrical System - Cables Amended:120907


CABLESUsed on and up to Chassis No 4161

1 440699 1 Cable - Battery negative - to chassis earth (black)2a 440700 1 Cable - battery link2b 442868 1 Cable - battery link - Fusible - 600A OL1514-2

3 440701 1 Cable - battery to master switch (red)4 430056 1 Cable - master switch to fuses - 40A (brown)5 430055 1 Cable - master switch to fuse - 125A (red)6 430705 1 Link - 40A fuses

7a 439871 1 Cable - 40A fuse to REDC plug (Black connector)8 440787 2 Cable - REDC pos+ / neg - PCB (Black connector)9 439843 1 Cable - 40 A fuses to FEDC

10 439795 1 Cable - FEDC pos+ / neg- (brown)11 440709 1 Cable - Master switch to starter (5.25 M wheelbase)12 440708 1 Cable - starter to 175A fuse13 440707 1 Cable - 175A fuse to alternator (Red )14 440705 1 Cable - Alternator to chassis earth15 440704 1 Cable - starter to chassis earth 16 424991 1 Link - 175A to 150A fuses17 440703 1 Cable - 150A fuse to REDC (Red connector)18 439895 1 Cable - to grid heater 125A fuse (Red connector)19 431857 1 Braid - earth - engine20 439834 1 Cable - fuse 125A21 439784 1 Cable - fuse to front PCB

Used from 4162 & up to Chassis No 5114 excluding 4625 & 47527b 441598 1 Cable - negative - REDC (Blue connector)8b 441255 1 Cable - negative - REDC22 441599 1 Cable - positive - REDC (Blue connector)23 441257 1 Cable - Positive - REDC

PARTS MANUAL


ENVIRO 400


Electrical System - Harnesses Amended:270907


HARNESSES - Euro 4 - Used on and up to Chassis No 4306 (Beige Engine)436149 1 Harness - CAN BUS - IOU1 to IOU2439442 1 Harness - CAN BUS - FEDC to Binnacle FEDC424614 1 Pad - neoprene - main harness run439684 1 Harness - CAN -FEDC440797 1 Harness - front EDC - Used on & up to chassis No 4082 not including 4074 E1519A&B441725 1 Harness - front EDC - Used on & after chassis No 4083 including 4074 E1519C&D442599 1 Harness - front EDC with speed limiter (WPO53367) E1519G441727 1 Link - front EDC harness - Voith441728 1 Link - front EDC harness - ZF440340 1 Harness - REDC - Voith441089 1 Harness - REDC - ZF440710 1 Harness - rear 441074 1 Harness - front - ZF Transmission440712 1 Harness - front - Voith Transmission441318 1 Harness - ABS - front440831 1 Harness - ABS - rear439684 1 Harness - CAN -FEDC - Voith Transmission440706 1 Harness - engine - auxiliary441357 1 Harness - chassis engine442598 1 Harness - chassis engine - with speed limiter WPO53367440839 1 Harness - rear kneel levelling valves SS1511J440802 1 Harness - Sub Diagnostic7680006NO3 1 Harness - wheechair arm link AL1547 -1 441060 1 Harness - Urea doser unit extension441085 1 Harness - Urea tank extension440983 1 Harness - ramp extension440916 1 Harness - external stop AL1548 -2



Electrical System - Harnesses Amended:130209


HARNESSES - EURO 4+ & 5-. Used on and after Chassis No 4307 (Red Engine)442473 1 Harness - REDC - Voith EM1519E442638 1 Harness - REDC - ZF EM1519F442640 1 Harness - ABS - front442490 1 Harness - chassis engine

AUXILIARY BODY HARNESSES AL1553-1444983 1 Harness - heating and lights445032 1 Harness - air con clutch

DIAGNOSTIC SOCKET - ENGINE BAY (Located near Stop/ Start buttons)660500 1 Diagnostic connector - 9 way660831 A/R Pin - gold (0.5 - 2.4)659105 A/R Pin - gold (1.0 - 2.0)660819 A/R Pin - gold (0.5 - 1.3)660428 1 Cap - diagnostic connector

PARTS MANUAL


ENVIRO 400

Electrical System - Miscellaneous Amended:140906


1

119

5

432

12

STOP

76

START

EMERGENCY STOPPRESS TO STOP

START SWITCHPRESS TO START

10

REVERSEINTERLOCK

BUTTON

MUST BE PRESSEDWITHIN 2 SECS OF

SELECTING REVERSE

R

8



Electrical System - Miscellaneous Amended:120111


MISCELLANEOUS1 658755 1 Air temperature sensor (front crossmember)

429545 1 Grommet - temperature sensor2 655689 1 Horn - high tone

76270003 1 Reverse horn3a 610369 9 Rubber boot - Master switch / starter / alternator.3b 611783 3 Rubber boot - Master switch / starter

4 401919 1 Bracket - slotted “L” - Ø 12.5 hole 5 427380 1 Bracket - slotted “L” - Ø 15.0 hole6 424441 1 Bracket - slotted - angled

7a 443392 1 STOP button assembly - external stop - side - 2000mm - bus side AL1548-27b 443352 1 STOP button assembly - Rear Engine Frame - 190mm - engine bay AL1548-17c 443351 1 START button assembly - Rear Engine Frame

659812 1 START switch8 441043 1 Bracket - pressure switch mounting9 439599 1 Label - rear stop/start (yellow)

10a 658812 1 Steering column switch - RH10b 661710 1 Steering column switch - RH - (Used on & after Chassis No 5115) Multic panel10c 657886 1 Steering column switch - LH OL1537-1

661710 1 SWITCH-STRG COLUMN RH11 660358 1 Reverse interlock button assembly12 414566 1 Label - Reverse interlock

PARTS MANUAL


ENVIRO 400

Battery Carrier Amended:

Unit No: BC1511F

15

14

64

8

7

5

1

312

2

10

16

13

BC1410F

4

5

9

9


Unit No: BC1511F

Battery Carrier Amended:231008


1 436624 1 Battery carrier tray assembly434275 1 Liner - carrier tray445057 1 Mat - batteries

2 426395 1 Slide - LH3 426396 1 Slide - RH

MCN 508P 20 Nut - slideMCS 108 20P 18 Screw - slideMCS 108 25P 2 Screw - slide

4 420616 4 Roller assembly comprising:656359 4 Roller420617 4 Bearing606614 A/R Loctite

5 656382 4 Circlip6 420701 4 Shaft - roller

MCN 220P 4 NutWMA 20SP 4 Washer

7 656376 2 Fastener “Antiluce”437575 2 Spacer - fastenerMCN 512P 2 Nut

8 430625 2 Retaining bracketMCS 110 25P 3 SetscrewWMA 10SP 3 WasherMCN 510P 3 Nut

9 436625 2 Battery Retainer channelMCS 106 30P 1 ScrewMCS 106 70P 2 SetscrewWMA 6SP 8 Washer- plainWMC 6SP 4 Washer - spring109400 4 Washer - flatMCN 106P 12 Nut

PARTS MANUAL


ENVIRO 400


Unit No: BC1511F

15

14

64

8

7

5

1

312

2

10

16

13

BC1410F

4

5

9

9


Unit No: BC1511F



10 437117 1 “J” bolt - battery clamp11 656334 2 Battery 12v12 426411 1 Shield - rear13 422843 1 Shield - front14 437554 1 Battery cover assembly

437553 2 Plate - cover retainer660321 6 Rivet443756 1 Bracket - cover support - lower443755 1 Bracket - cover support - upperMCS-104-16P 2 ScrewMCN-704P 2 Nut

15 437857 1 Shield - air tank656818-1 1 Clip - teebolt - air tank

16 437630 1 Stay - battery carrierMCS-108-25P 2 ScrewMCN-508P 2 Nut - self locking

BATTERY BOOST SOCKET - OPTION AL 1513-2653847 1 Battery boost socket440840 1 Harness - boost socket

GEL BATTERY OPTION OL1533-1660736 2 Battery - Gel type440699 1 Battery negative - chassis (replaces 439942)440770 1 Battery link (replaces 440204)443317 1 Cable master switch - battery (replaces 440211)

PARTS MANUAL


ENVIRO 400

Battery Carrier & Rear Frame Area Amended:

Unit No: BC1511F/E1516C

1

2

4

MEGA150A

1110

7

8,9

40

REAR FRAME

2

MEGA175A

MEGA125

2

5

3

12

6


Unit No: BC1511F/E1519A,B,C&D

Battery Carrier & Rear Frame Area Amended:170209


Used on & up to Chassis No 5114 excluding 4625 & 47521 658431 1 Master switch

400622-51 4 Spacer - master switch to bracketMCS 106 30P 4 SetscrewWMA 6SP 8 Washer - plainMCN 506P 4 Nut self-lockingMCN 212P 2 Half nut - spacer

2 656081 3 Fuse holder - “Mega” 9.5 lbs ft3 660326-2 2 Fuse - 125A - green4 660326-3 2 Fuse - 150A - white5 660326-4 2 Fuse - 175A - orange6 424991 1 Link - fuse7 658869 3 Fuse holder - “Midi”8 430705 1 Link - midi fuse 9 658870 3 Fuse - 40A - green

10 610369 2 Rubber boot - 12mm11 611783 1 Rubber boot - 6mm12 651598-4 1 Add-A-Fuse - 5 Amp - Tan

PARTS MANUAL


ENVIRO 400


Unit No: IP1510A&B

0

4

5

6

3

1

9

8

2

11

17

10

16

12

15

1314

18

7a7b

1

2

9a

9b

9c

9d

1

2 1

2 12 1

443787

446858

443788

446859


Unit No: IP1510A&B



Used on & after Chassis No 4625, 4752, 5115 onwards443782 1 Binnacle assembly - MPH - 1 door IP1510A443783 1 Binnacle assembly - MPH - 2 door IP1510B446854 1 Binnacle assembly - MPH - 1 door - open & close IP1510F446855 1 Binnacle assembly - MPH - 2 door - open & close IP1510G

1 661704 1 Instrument panel - MPH2 445042 1 Binnacle - front3 445043 1 Binnacle - rear4 MCS-3806-16 11 Screw - hex socket5 661709 11 Clip - spring steel nut6 445041 1 Panel assemby - ignition 7 661871 1 Lighting switch 8 443786 1 Panel assembly - 15 button (body)

9a 443787 1 Panel assembly - Door / kneel - 1 Door - single button open & close 9b 446858 1 Panel assembly - Door / kneel - 2 Door - two button open & close9c 443788 1 Panel assembly - Door - 2 Door - single button open & close + Full kneel9d 446859 1 Panel assembly - Door - 2 Door - two button open & close + Full kneel10 445047 1 Button assembly - start / stop11 445044 1 Column shroud assembly12 660909-2 1 Top shroud cover13 660909-3 1 Rear shroud cover14 661708 6 Screw15 445055 1 Blanking cap16 444264 1 Clamp half17 448827 1 Binnacle support bracket18 445046 1 Blanking plug

660913-2 1 OBD plug housing662241 a/r LED - switches

PARTS MANUAL


ENVIRO 400

Electrical System - Front - EDC Amended:

Unit No: E1523A

3

9

10

4 5 6

BLINKCODE

8

445288/445247-FRT

2

12

IOU

CA

MU

1

11

7

12


Unit No: E1523A

Electrical System - Front - EDC Amended:260509


Used on & after Chassis No 4625, 4752, 5115 onwards445247 1 Front EDC assembly

1 444203 1 Mounting plate2 659973 1 Control unit - CAMU3 659972 2 Control unit - IOU4 612314-6 1 Switch - “Retarder” - Green

612319-76 1 Lens - “retarder5 612314-6 1 Switch - “Blink code” - Yellow

612319-85 1 Lens - “Blinkcode”6 612317 1 Blanking plug7 612316 1 Switch housing - 3 way8 426290 1 Bracket - diagnostic switches9 660811 1 ABS ‘E’ control unit

10 445894 1 PCB assembly - front EDC- c/w fixings (See separate list)11 446546 1 Bracket - FEDC connections12 654200 3 Rubber boot13 Refer to body manual 1 Intellitec current monitor (where intellitec lighting system is fitted)

445609 1 Harness - front EDC - universal445895 1 Label - FEDC

PARTS MANUAL


ENVIRO 400

Electrical System - PCB - Front - EDC Amended:

Unit No:E1523A,445894

35

F12

F13

F14

F15

F16

F17

F18

F19

F20

F21

F22

F23

F24

F25

F26

F27

F28

F1

F2

F3

F4

F5

F29

F30

F31

F32

F33

F34

F6

F7

F8

F9

F10

F11

R1

R2

torq

ue

3,9

Nm

BA

TT

+30

torq

ue

17 N

m

GN

D31to

rque

3,9

Nm

SW

BA

TT

+30A

Ignitio

n

ALE

XA

ND

ER

-DE

NN

ISP

CB

- F

RO

NT

- E

DC

PT. N

O 4

39617

9

11

13

9

10

14

1,15

10

445894

3A

10A

15A

20A

21

3

6

7

8

1

5A 4

7.5A 5

20

30

40

35

25


Unit No:E1523A,445894

Electrical System - PCB - Front - EDC Amended:


Used on & after Chassis No 4625, 4752, 5115 onwards445894 1 PCB assembly - front EDC

1 439610 1 PCB board2 651598-12 A/R Add-A-Fuse - 1 Amp - Black3 651598-4 A/R Add-A-Fuse - 5 Amp - Tan4 651598-2 A/R Add-A-Fuse - 3 Amp - Violet5 651598-2 A/R Add-A-Fuse - 7.5 Amp - Brown6 651598-6 A/R Add-A-Fuse - 10 Amp - Red7 651598-7 A/R Add-A-Fuse - 15 Amp - Blue8 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow9 656674 1 Fuse - “maxi” - 20 Amp - Yellow

10 660060 1 Fuse - “maxi” - 25 Amp - Grey11 656548 2 Fuse - “maxi” - 30 Amp - Green12 660061 1 Fuse - “maxi” - 35 Amp 13 657794 1 Fuse - “maxi” - 40 Amp - Orange14 657023 1 Relay - ignition15 660721 4 Stand off assembly - c/w screws

PARTS MANUAL


ENVIRO 400


Unit No: E1523A

IOU

NOXSENSOR

8

445346/44523 2

7

1

4

GEARBOX ECU

6 5


Unit No: E1523A



Used on & after Chassis No 4625, 4752, 5115 onwards445248 1 Rear EDC assembly

1 443227 1 Mounting plate - rear EDC2 659972 1 Control unit - IOU 3 445884 1 PCB assembly - rear EDC (See separate list)4 654200 3 Rubber boot5 415701-105 1 Label - “Nox Sensor”6a 660879 1 Electronic control unit - Voith transmission6b 660940 1 Electronic control unit - ZF transmission 7 442637 1 Bracket - EDC connections8 655933 1 Relay - starter9 Refer to body manua 1 Dual Channel Current Monitor

445250 1 Harness - rear EDC445395 1 Label - fuses - REDC

PARTS MANUAL


ENVIRO 400

Electrical System - PCB - Rear - EDC Amended:

Unit No:E1523A,445894

10

11

12

1,13

10

5A

10A

15A

20A

8

7

3A

7.5

6

7

2

3

4

5

F2

4S

PA

RE

F2

3

F4

F3

F2

F1

torq

ue

3,9

Nm

BA

TT

+

30

torq

ue

17 N

m

GN

D

31

torq

ue

9N

m

SW

BA

TT

+

30A

Coola

nt

Module

- L

ow

er

Coola

nt

Module

- U

pperF

uel H

eate

r

F1

4

F1

5

F1

6

F1

9

F2

0

F2

1

F1

0

F11

F1

2

F1

3

F1

7

F1

8

F2

2

F5

F6

F7

F8

F9

IGNITION

ALE

XA

ND

ER

-DE

NN

IS

PC

B -

RE

AR

- E

DC

PT.

NO

439609

445884

30

20


Unit No: E1523A, 439616

Electrical System - PCB - Rear - EDC Amended:


Used on & after Chassis No 4625, 4752, 5115 onwards445884 1 PCB assembly - Rear EDC

1 439609 1 PCB board2 651598-2 A/R Add-A-Fuse - 3 Amp - Violet3 651598-4 A/R Add-A-Fuse - 5 Amp - Tan4 651598-5 A/R Add-A-Fuse - 7.5 Amp - Brown5 651598-6 A/R Add-A-Fuse - 10 Amp - Red6 651598-7 A/R Add-A-Fuse - 15 Amp - Blue7 651598-8 A/R Add-A-Fuse - 20 Amp - Yellow8 656674 1 Fuse - “maxi” - 20 Amp - Yellow9 656548 6 Fuse - “maxi” - 30 Amp - Green

10 437840 1 Coolant module 11 651438 1 Relay12 657023 1 Relay13 660721 4 Stand off assembly - c/w screws

PARTS MANUAL


ENVIRO 400

Unit No: E1523A

Electrical System - Harnesses Amended:


Used on and After Chassis No 5115HARNESSES

445245 1 Harness - front - ZF Transmission443827 1 Harness - ABS - front443826 1 Harness - ABS - rear445244 1 Harness - engine - auxiliary445246 1 Harness - chassis engine445366 1 Harness - link - ZF445250 1 Harness - rear EDC


Unit No: E1521A

Electrical System - Cables Amended:


Used on & after Chassis No 4625, 4752, 5115 onwardsCABLES

439942 1 Cable - Battery negative - to chassis earth (black)440204 1 Cable - battery link440211 1 Cable - battery to master switch (red)430056 1 Cable - master switch to fast fuses430055 1 Cable - master switch to fuse - 125A (red)440709 1 Cable - Master switch to starter445067 1 Cable - Master switch fuse & ground443824 1 Cable - negative - REDC443825 1 Cable - Positive - REDC443816 1 Cable - positive - engine bay fuse445068 1 Cable- battery positive to FEDC440708 1 Cable - starter to 175A fuse440707 1 Cable - 175A fuse to alternator440705 1 Cable - Alternator to starter440704 1 Cable - starter to frame446179 1 Link - coolant top up431857 1 Braid - earth - engine

PARTS MANUAL


ENVIRO 400


Unit No: BC1511F/E1521A/AL1513-2

1

2

3

MEGA125A

109

6

7,8

40

REAR FRAME

2

MEGA175A

MEGA125

2

4

3

11

5


Unit No: BC1511F/E1521A/AL1513-2



1 658431 1 Master switch 400622-51 4 Spacer - master switch to bracketMCS 106 30P 4 SetscrewWMA 6SP 8 Washer - plainMCN 506P 4 Nut self-lockingMCN 212P 2 Half nut - spacer

2 656081 3 Fuse holder - “Mega” 9.5 lbs ft3 660326-2 2 Fuse - 125A - green4 660326-4 2 Fuse - 175A - white5 424991 1 Link - fuse6 658869 2 Fuse holder - “Midi”7 430705 1 Link - midi fuse 8 658870 2 Fuse - 40A - green9 610369 2 Rubber boot - 12mm

10 611783 1 Rubber boot - 6mm11 651598-4 1 Add-A-Fuse - 5 Amp - Tan

BATTERY BOOST SOCKET AL1513-2653847 1 Boost socketMCS 1306 20P 6 ScrewMCN 106P 6 NutWMC 6SP 6 Washer - spring440840 1 Cables - boost socket

PARTS MANUAL



Contents

Suspension, Frame, Wheels Amended:

Suspension

Air suspension system - Full Kneel . . . . Page 6.2 - 5

Air suspension system - Front Kneel . . . Page 6.6 - 9

Used on & up to Chassis No 5114 excluding 4625 & 4752

Front air suspension - Dana . . . . . . . . . Page 6.10 - 13

Used on & after Chassis No 4625, 4752, 5115 onwards

Front air suspension - ZF . . . . . . . . . . . Page 6.13

Rear air suspension . . . . . . . . . . . . . . . . Page 6.14 - 17

Levelling valve linkage . . . . . . . . . . . . . . Page 6.18 - 19

Frame

Frame assembly . . . . . . . . . . . . . . . . . . Page 6.20 - 21

Rear Frame assembly . . . . . . . . . . . . . . Page 6.22 - 23

Cab Floor

Cab Floor/Foot Controls . . . . . . . . . . . . Page 6.24 - 25

Wheels

Wheel and Tyres . . . . . . . . . . . . . . . . . . Page 6.26 - 6.27

Section 6

PARTS MANUAL


ENVIRO 400

Air Suspension - Full Kneel Amended:

Unit No: SS1511J,SS1513A

43 42 4112

23 22

21

11/25

2121

21

21

6

3

1

24

3

2

12 BLACK

12 GREEN

6 GREEN6 BLACK6 BLUE

KEY TO PIPE SIZES

21

211

1

1

43

42

41

12

23

22

21

11/25

24

3

21 211

AR7794



3

1

2

FROMPORT 24

MCPV

FULL KNEEL REAR LOCATION

FRONTLOCATION

21

FRONT KNEEL

FULL KNEEL

ZF GEARBOXSUPPLY

24

TO STEERINGCOLUMN

PILOT VALVE

32

SOLENOID�VALVE

LEVELLING�VALVE

RH-FRONT

LEVELLING�VALVE

LH-FRONT

CHARGINGVALVE

REAR

FRONT

LEVELLING�VALVE

RH-REAR

LEVELLING�VALVE

LH-REAR

SOLENOID�VALVE

SOLENOID�VALVE

SOLENOID�VALVE

8

2

1221

24

13

21

24

4

13

8

89

14

11

23

2

18

2

23

8

2124

2122

9

8

8

20 1

22

17,16,15

25

13

6

8

15161711

13

11

14

11

11

10

6

7

5

7

3

1

27

28

25

27

28

29

10

19

19

226

7

3

5

27

28

29

30

30

22

31

4


Unit No: SS1511J,SS1513A

Air Suspension - Full Kneel Amended:1300710


1 655711 1 Charging valve2 654919-4 - Elbow3 654931 - Connector

4a 656606 2 Solenoid valve - 3 way (Used on and up to Chassis No 5114) SS1511J4b 661657 2 Solenoid valve - 3 way (Used on and after Chassis No 5115) SS1513A

5 654923-2 - Tee piece6 654919-8 - Elbow7 654921-4 - Connector8 654919-5 - Elbow9 660076 2 Levelling valve - front (see separate list)

10 652582 2 Levelling valve - rear (see separate list)11 612525 - Plug - levelling valve12 656607 2 Solenoid valve - single 13 661723 - Tee piece - swivel14 654921-8 - Connector15 654339 - Nut16 654340 - Olive17 655832-2 - Sleeve18 654920-2 - Elbow assembly19 655710 1 Line filter

655710-1 1 Filter element20 657217 - Connector21 656919-3 - Elbow22 654921-4 - Connector23 659800 2 Air spring - front (see separate list)24 438935 4 Air spring - rear (see separate list)25 660222 - “F” fitting26 661727 - Elbow27 657920 - Tee piece

PARTS MANUAL


ENVIRO 400


Unit No: SS1511J

43 42 4112

23 22

21

11/25

2121

21

21

6

3

1

24

3

2

12 BLACK

12 GREEN


KEY TO PIPE SIZES

21

211

1

1

43

42

41

12

23

22

21

11/25

24

3

21 211

AR7794



3

1

2

FROMPORT 24

MCPV

FULL KNEEL REAR LOCATION

FRONTLOCATION

21

FRONT KNEEL

FULL KNEEL

ZF GEARBOXSUPPLY

24

TO STEERINGCOLUMN

PILOT VALVE

32

SOLENOID�VALVE

LEVELLING�VALVE

RH-FRONT

LEVELLING�VALVE

LH-FRONT

CHARGINGVALVE

REAR

FRONT

LEVELLING�VALVE

RH-REAR

LEVELLING�VALVE

LH-REAR

SOLENOID�VALVE

SOLENOID�VALVE

SOLENOID�VALVE

8

2

1221

24

13

21

24

4

13

8

89

14

11

23

2

18

2

23

8

2124

2122

9

8

8

20 1

22

17,16,15

25

13

6

8

15161711

13

11

14

11

11

10

6

7

5

7

3

1

27

28

25

27

28

29

10

19

19

226

7

3

5

27

28

29

30

30

22

31

4


Unit No: SS1511J



28 657921-1 - Reducer29 655017 - Tee piece30 654923-1 - Tee piece31 654621-9 - Connector32 654919-8 - Elbow

PARTS MANUAL


ENVIRO 400

Air Suspension - Front Kneel Amended:

Unit No: SS1510H

12121

1 2121

6

3

12

12 BLACK

12 GREEN


KEY TO PIPE SIZES

12121

434241 12

2322

21

11/25

24

3

CHARGING VALVE


FRONTLOCATION

12121

2 1 3

STEERING COLUMNPILOT VALVE

LEVELLING�VALVE

RH-REAR

SOLENOID�VALVE

LEVELLING�VALVE

LH-REAR

LEVELLING�VALVE

RH-FRONT

LEVELLING�VALVE

LH-FRONT

REAR

FRONT

SOLENOID�VALVE

5

5

3

21

19

14

14

21

19

11

16

17

10

16

13

1612

16

18

5

16

6

18

16

20

19

16

17

20 21

19

13

10

16 21

23

AR7795

29

30

29

8,9,10

2930

4

15

212221

17

26

25

24

2528

27


Unit No: SS1510H

Air Suspension - Front Kneel Amended:020708


1 655711 1 Charging valve2 654919-4 - Elbow3 657217 - Connector4 656606 2 Solenoid valve - 3 way5 654919-4 - Elbow6 654920-2 - Elbow assembly7 656607 2 Solenoid valve - single8 654339 - Nut9 654340 - Olive

10 655832-2 - Sleeve11 655007 - Tee piece12 654921-8 - Connector13 660076 2 Levelling valve - front (see separate list)14 652582 2 Levelling valve - rear (see separate list)15 612525 - Plug 16 654919-5 - Elbow17 654921-8 - Connector18 659800 2 Air spring - front (see separate list)19 438935 4 Air spring - rear (see separate list)20 654919-3 - Elbow21 654921-9 - Connector22 654922 - Tee piece23 655710 1 Line filter

655710-1 1 Filter element24 655017 - Tee piece25 654921-1 - Tee piece26 6549919-8 - Elbow27 654921-4 - Connector28 654921-9 - Connector

PARTS MANUAL


ENVIRO 400


Unit No: SS1510H

12121

1 2121

6

3

12

12 BLACK

12 GREEN


KEY TO PIPE SIZES

12121

434241 12

2322

21

11/25

24

3

CHARGING VALVE


FRONTLOCATION

12121

2 1 3

STEERING COLUMNPILOT VALVE

LEVELLING�VALVE

RH-REAR

SOLENOID�VALVE

LEVELLING�VALVE

LH-REAR

LEVELLING�VALVE

RH-FRONT

LEVELLING�VALVE

LH-FRONT

REAR

FRONT

SOLENOID�VALVE

5

5

3

21

19

14

14

21

19

11

16

17

10

16

13

1612

16

18

5

16

6

18

16

20

19

16

17

20 21

19

13

10

16 21

23

AR7795

29

30

29

8,9,10

2930

4

15

212221

17

26

25

24

2528

27


Unit No: SS1510H



29 657920 - Tee piece30 657921-1 - Reducer

PARTS MANUAL


ENVIRO 400

Front Air Suspension Amended:080212

Unit No: SF1511C, SF1512A. DF1510A

15

FRONT

18

PROXIMITY SWITCHARRANGEMENT - ZF AXLE

PROXIMITY SWITCHARRANGEMENT - DANA AXLE

33

30

34

20

19

2

ZF AXLELH

ZF AXLE

RH

DANA AXLE SHOWN

24

22

22

23

26

2728 29

25

21

31

3032

SF1511

25

24

23

23

23

FRONT

13a

14

15

14a

15

LOW

ER

LIN

K

UPPER LINK

13b

14a

13a

14b

1617

16

16

17





Used on & up to Chassis No 5114 excluding 4625 & 4752 SF1511CFRONT SUSPENSION - DANA FRONT AXLE

1 419799 2 Torque arm - lower657691 2 Repair kit

2 10 MCB 118 50D 8 Bolt 309-332 lbs ft3 428111 2 Torque arm - upper

651697-1 2 Repair kit4 10 MCB 116 160D 4 Bolt 219-243 lbs ft5 10 MCB 116 55D 4 Bolt6 10 MCN 516 4 Nut special

7a 427970 1 Tower - LH - (Dana Front Axle) SF1511C8a 427971 1 Tower - RH - (Dana Front Axle) SF1511C

9 10 MCS 120 45D 4 Screw - tower to axle bed - front 427-471 lbs ft10 428107 1 Anti roll bar11 434216 4 Rubber- mounting - A.R.B - half Fit as pairs12 MCB 112 35P 8 Bolt - bush to frame 101-111Nm / 75-82Nm13a 425529 2/1 Link plate - ARB - (3 hole) Dana & ZF axle14a 425531 2/1 Link plate & spacer assembly - ARB - (3 hole) Dana & ZF axle15 438257 8 Rubber- mounting - A.R.B - link plate16 10MCB 116 90D 6 Bolt17 10 MCN 516 6 Nut 276 lbs ft

18a 433915 1 Block mounting (Dana Front Axle)19a 10MCB 120 140D 4 Bolt - (Dana Front Axle)

20 WMA 16SP 8 Shim - link-top21 657610 2 Damper- c/w mounting kit DF 1400A22 657610-1 4 Rubber mounting c/w sleeve 23 657696-3 8 Retaining washer - upper & lower24 657696-4 2 Nut

PARTS MANUAL


ENVIRO 400



15

FRONT

18

PROXIMITY SWITCHARRANGEMENT - ZF AXLE

PROXIMITY SWITCHARRANGEMENT - DANA AXLE

33

30

34

20

19

2

ZF AXLELH

ZF AXLE

RH

DANA AXLE SHOWN

24

22

22

23

26

2728 29

25

21

31

3032

SF1511

25

24

23

23

23

FRONT

13a

14

15

14a

15

LOW

ER

LIN

K

UPPER LINK

13b

14a

13a

14b

1617

16

16

17



Front Air Suspension Amended:


21 657610 2 Damper- c/w mounting kit DF 1400A22 657610-1 4 Rubber mounting c/w sleeve 23 657696-3 8 Retaining washer - upper & lower24 657696-4 2 Nut25 659800 2 Air spring assembly

MCB 112 55P 2 Bolt - air spring piston to tower 55 lbs ftMCN 710P 4 Nut - top plate to piston 414 lbs ftWMC 12SP 2 Spring washer

26 659800-4 2 Top plate assembly650055 A/R Jointing compound - top plate sealing

27 656298-2 2 Diaphragm28 659800-2 2 Piston29 659800-3 2 Bump stop30 657505 1 Proximity switch Set gap 0.236 --0.250”

WMG 18SP 2 Washer 424998 1 Cable assembly - Proximity switch

31 434586 1 Plate - sensor flag Proximity switch32 421487 1 Bracket - proximity switch mounting Welded component

FRONT SUSPENSION - ZF FRONT AXLE - all other items as aboveUsed on & after Chassis No 4625, 4752, 5115 onwards SF1512A

7b 445209 1 Tower - LH - (ZF Front Axle)8b 445211 1 Tower - RH - (ZF Front Axle)

13b 445307 1 Link plate - ARB - 4 hole (ZF Front Axle)14b 445314 1 Link plate with spacer - ARB - 4 hole (ZF Front Axle)18b 445212 1 Block mounting (ZF Front Axle)19b 10MCB 120 160D 4 Bolt - (ZF Front Axle)

31 434586 1 Angle - sensor flag Proximity switch

PARTS MANUAL


ENVIRO 400

Rear Suspension Amended:

Unit No: SR1510B, DR1510A

26

27

28

25



Rear Suspension Amended:260509


1 422590 1 Anti roll bar2 423725 2 Link - Anti roll bar3 434214 4 Bearing - Anti roll bar4 423738 4 Spacer - bearing to link5 MCB 112 55P 8 Bolt6 MCN 512P 8 Nut7 422608 1 Mounting bracket - Anti roll bar - RH8 422607 1 Mounting bracket - Anti roll bar - LH9 425375 2 Pin 230-260Nm

10 658973 4 Mounting rubber - roll bar eye11 423615 2 Washer - inner12 WMA 16SP 2 Washer- outer13 MCN 516P 4 Nut-self locking14 MCS 3316 30P 2 Screw- countersunk15 MCS 116 25P 2 Bolt16 MCS 116 30P 4 Bolt

606152 A/R Loctite HO-242 (apply to 14, 15 & 16)17 404264-1 2 Washer - bottom18 404264-2 2 Washer - top19 434947 4 Mounting rubber - link plate20 MCN 520P 2 Nut - self locking21 659921-22 2 Control arm - upper (576mm)22 659921-23 2 Control arm - lower (664mm)23 10MCS-118-55D 8 Screw - torque arm to frame / axle casing (390Nm to axle & 353-438 Nm to frame)

WLA 12SP A/R Washer - torque arms24 657611 4 Damper- c/w mounting kit

657610-1 2 Rubber mounting c/w sleeve657696-3 3 Retainer657696-4 4 Lock nut

PARTS MANUAL


ENVIRO 400

Rear Suspension Amended:


26

27

28

25



Rear Suspension Amended:130209


25 657130 1 Air spring assembly - LH & RHMCB 112 35P 2 Bolt - air spring piston to tower 75NmMCN 710P 4 Nut - top plate to piston 17-20NmWMC 12SP 2 Washer - spring

26 657130-1 4 Top plate assembly - L.H650055 A/R Jointing compound - top plate sealing

27 656299-2 4 Diaphragm28 651461-13 4 Piston

PARTS MANUAL


ENVIRO 400

Levelling Valve Linkage Amended:

Unit No: SS1511J & SS1510H

REAR - R.H REAR - L.H

FRONT - L.H FRONT - R.H

2

43

43 4

3

43

1 1

2

8

8

8

8

10

12

5

12

7

10

12

5

12

7

10

12

5

12

7

13

13

11 13

11

11

14 15

9

99

9

AR7792

10

12

5

12

7

13

13

131415

12


Unit No: SS1511J & SS1510H

Levelling Valve Linkage Amended:120111


660076 2 Levelling valve assembly - Front 652582 2 Levelling valve assembly - Rear400622-39 4 Spacer to frame MCB 108 50P 4 Bolt - front valvesMCB 108 80P 4 Bolt - rear valvesMCN 508P 8 NutWMA 8SP Washer - plain

1 436179 1 Lever arm - front2 439280 1 Lever arm - Rear3 MCS 108 16P 4 Setscrew - lever arm4 WMC 8SP 4 Washer - spring5 419951-4 2 Connecting Rod - Front6 419951-6 2 Connecting Rod - Rear7 659694 4 Pressure plate assembly - upper - M6 - c/w clip8 MCN 506P 4 Nut9 WMA 6SP 4 Washer - Spring

10 655691-1 2 Pressure plate assembly - lower - c/w clip11 437478 2 Pin - pressure plate12 655691-2 A/R Clip - pressure plate13 MCN 108P 12 Nut14 WMC 6SP 2 Washer - Spring15 438400 1 Anchor plate - levelling valve -front

MCS 106 16P 4 Bolt - brackets to towerWMC 6SP 4 Washer - Spring

PARTS MANUAL


ENVIRO 400

Frame Assembly Amended:080107

Unit No: F1523A&B,F1524A&B,NS1510B&C

2

1

3 4

8

12

9105,6,7

ALEXANDER DENNIS

11





1a 440658 1 Frame assembly - 5.25m - Voith transmission F1523A1b 442180 1 Frame assembly - 5.25m - Voith transmission - wheelarch tank F1523B3a 440290 1 Front module4a 439212 1 Centre module - 5.25m - 2 door5a 440629 1 Rear module

1c 440917 1 Frame assembly - 5.95m - ZF transmission - F1524A1d 441852 1 Frame assembly - 5.95m - ZF transmission - wheelarch tank F1524B1e 442453 1 Frame assembly - 5.25m - ZF transmission F1523C2b 440290 1 Front module3b 439212 1 Centre module - 5.95m - 2 door4b 440629 1 Rear module

5 439234 1 Front crossbeam - “Z”6 MCS 112 35P 4 Screw7 MCN 512P 4 Nut

Used on & up to Chassis No 4164 NS 1510B8a 424293 1 Noise pad- LH9a 440670 1 Noise pad - centre

10a 424300 1 Noise pad - RH657085 16 Clip - noisepad

Used on & after to Chassis No 4165 NS1510C8b 441866 1 Noise pad- LH9b 441867 1 Noise pad - centre

10b 441868 1 Noise pad - RH11 441869 1 Noise pad - Centre - Lower

657085 16 Clip - noisepad

12 438978 1 Plate - vehicle identification number

PARTS MANUAL


ENVIRO 400



1

7,85

3 4

2

1111

2

611,13,14

12,9,10 11,9,10

2


Unit No: F1523,NS1510B



1 440737 1 Rear lower channel2 MCS 110 25P 18 Screw3 432842 1 Rear upright angle - LH4 424607 1 Rear upright angle - RH5 422573 1 Skirt angle - LH6 439797 1 Skirt angle - RH (For engine mount details see Pages 2.66 - 2.76)

430532-1 A/R Shim - eng mounting member - 0.8 mm430532-2 A/R Shim - eng mounting member - 1.0 mm430532-3 A/R Shim - eng mounting member - 1.2 mm

7 MCS 112 45P 3 Screw - skirt to frame8 MCN 512P 3 Nut9 426497 2 Tapping plate - 3 hole

10 WMC 10SP 6 Spring washer11 MCS 112 30P 9 Screw 12 MCS 110 45P 6 Screw13 MCS 112 35P 1 Screw 14 MCN 510P 6 Nut

PARTS MANUAL


ENVIRO 400

Cab Floor & Foot Controls Amended:

Unit No: EC1511C&D

3

4

1

2


Unit No: EC1511C&D

Cab Floor & Foot Controls Amended:120907


1 660687 1 Footbrake pedal - (See braking system)MCS 108 30P 2 Setscrew655185 1 Washer - largeWMA 8SP 1 Washer - spring

2 661198 1 Thottle pedal - used on and after Chassis No 4228 (660583)661219 1 Kit - Adaptor plate

3 657404 1 Foot button valve

4 658740 1 Steering column adjustable (See Steering section)

NOTE:When a vehicle orginally fitted with obselete throttle pedal 660583 isfitted with new pedal 661198, an adaptor plate kit will be needed.

PARTS MANUAL


ENVIRO 400

Wheels and Tyres Amended:120907

Unit No: W1510C,F&G

23

1

MICHELIN

4/5/6


Unit No: W1510C,F,G&H

Wheels and Tyres Amended:170209


Used on and uo to Chassis No 4423 ACN 20761a 657297-17 6 Wheel and tyre assembly - Silver W1510C2a 657296-2 6 Wheel rim `3a - 6 Tyre - 305/70R - 22.5” - Michelin XZU+

Used on and After Chassis No 4424 ACN 20761b 657297-20 6 Wheel and tyre assembly - Silver W1510F2b 657296-2 6 Wheel rim3b - 6 Tyre - 305/70R - 22.5” - Michelin Intercity XZU 3

1c 657297-21 6 Wheel and tyre assembly - blue W1510G2c 658314 6 Wheel rim - blue3c - 6 Tyre - 305/70R - 22.5” - Michelin intercity XZU 3

1c 657297-22 6 Wheel and tyre assembly W1510H2c 657296-3 6 Wheel rim - silver3c - 6 Tyre - 305/70R - 22.5” - Goodyear Metro MCS

4 650723-4 20 Wheel nut - front5 651043-4 20 Wheel nut - rear6 245183-2 20 Cover - wheel nut - black

WHEEL EMBELLISHERS AL512-1660092 2 Embellisher

PARTS MANUAL


ENVIRO 400

Wheels and Tyres Amended:

Unit No:OL1539-1

23

1

MICHELIN

ALCOA

ALCOA

ALCOA

ALCOA

ALCOA

ALCOA

ALCOA

ALCOA

ALCOA

ALCOA

4/5

ALCOA 6


Unit No: OL1539-1

Wheels and Tyres Amended:


1 661202-1 6 Wheel and tyre assembly2 661186 6 Alloy wheel - 22.5” x 8.25” - offset 6.7”3 - 6 Tyre - 305/70R - 22.5” - Michelin XZU+

4 660438-1 20 Wheel nut - sleeved - short - single wheel 5 660438-2 20 Wheel nut - sleeved - long - twin wheel6 661081 40 Wheel nut cover


Contents

Steering and Front Axle Amended:180209

SteeringSteering Column - air adjustable . . . . . . Page 7.2 - 5Steering Column - air adjustable - spares Page 7.6 - 7Steering Column adjustment - air diagram Page 7.8 - 9

Front Axle - DanaSwivel Hub assembly . . . . . . . . . Page 7.10 - 15Swivel pin kits . . . . . . . . . . . . . . Page 7.16 - 17Hub and Brake assembly . . . . . . Page 7.18 - 19

Front Axle - ZFSwivel Hub assembly . . . . . . . . . Page 7.20 - 21Axle Beam . . . . . . . . . . . . . . . . . Page 7.22 - 23

Section 7

PARTS MANUAL


ENVIRO 400

Steering Column Amended:

Unit No: SG1510H

1

2/9

4

3

5

6

7

8

10


Unit No: SG1510H

Steering Column Amended:29.07.09


1 427483 1 Steering wheel427923 1 Badge - steering wheel - “DENNIS” OL1535-1440672 1 Badge - steering wheel - “ALEXANDER DENNIS”654449-12 1 Nut

2 658740 1 Steering column assembly (See separate list)3 433455 1 Shroud - steering column

MCB 112 120P 2 Setscrew - column to frameMCN 512P 2 Nut - setscrew - columnMCS 108 20P 4 Setscrew - column to cabWMC 8SP 4 Washer - spring658136 4 Washer

4 412555-8 1 Steering shaft607139 A/R Lubricator - splined shaft for spline

5 611511 1 Universal joint400546 3 Bolt - special 42 lbs ftMCN 410P 3 Nut - slotted further tightenSP5 16ST 3 Split pin to align split pin

6 659633 1 Steering gear408440-5 4 Bolt special 400-426 lbs ft421387 1 Bolt - forged 400-426 lbs ft659314-8 4 Washer - hardened

7 422673 1 Drop arm 405-446 lbs ft654660-1 1 Nut - stake type - drop arm

PARTS MANUAL


ENVIRO 400

Steering Column Amended:

Unit No: SG1510H

1

2/9

4

3

5

6

7

8

10


Unit No: SG1510H

Steering Column Amended:130111


Dana Front Axle only (orientation of clamps and bolt heads is important)8a 419801 1 Drag link assembly 210-230 Nm

653910 2 Ball joint656692-4 2 Bolt 70 - 80 Nm656692-3 2 NutSP10 32 ST 2 Split pin

ZF Front Axle only (orientation of clamps and bolt heads is important)8b 446999 1 Drag link assembly 210-230 Nm

653910 2 Ball joint656692-4 2 Bolt 70 - 80 Nm656692-3 2 NutSP10 32 ST 2 Split pin

9 439734 2 Packer10a 658812 1 Steering column switch - RH10b 661710 1 Steering column switch - RH - (Used on & after Chassis No 5115) Multic panel10c 657886 1 Steering column switch - LH OL1537-1

656602 2 Limiter assembly - steering box

PARTS MANUAL


ENVIRO 400

Steering Column Spares Amended:

Unit No: SG1510H

13139

8

177

9

6

1010

17

12

5 16

2

14,15

1

4

3

11

18

19


Unit No: SG1510H

Steering Column Spares Amended:


658740 1 Steering column assembly

1 658092-1 1 Column body assembly2 658740-2 1 Column and clamp assembly3 657115-2 1 Bevel box assembly4 658740-1 1 Slider assembly5 658092-5 1 Spring support spacer6 658092-6 1 Spring - RH7 658092-7 1 Spring - LH8 658092-8 1 Bolt - M10 x 1109 658092-9 2 Bonded aluminium washer

10 657115-11 2 Nut - M1211 657115-12 1 Patched bolt - M10 x 3512 657115-13 1 Nut - M1013 657115-15 2 End bracket14 657115-17 6 Washer - M815 657115-18 6 Setscrew - M8 x 1616 657115-20 1 Nylon tube - 1m17 655078-5 2 Washer18 654449-12 1 Nut, Nyloc -

3/4 -16 UNF

19 657115-24 1 Air piston clamp assembly

439734 a/r Angle steering column packer 2mm thick - column to frame

PARTS MANUAL


ENVIRO 400

Steering Gear Amended:

Unit No: SG1510H

4mmBlue

2

1

3 3

4

5

6

67

3

3,8

AR7059

98

AR6684

2

31PILOT VALVE OPERATION

3

1

2

SUPPLY FROMAUXILIARY &SUSPENSIONRESERVOIR

HANDBRAKEVALVE

6 m

mO

RA

NG

E6

mm

OR

AN

GE

6 mmORANGE

6 mmORANGE

31

2

21

1

SOLENOIDVALVE


LINE - Port 4

FEED FROM QUAD VALVE

TO INSTRUMENT PANEL

EXHAUST

EXHAUST

PILOTVALVE

4 mmBLACK

4 mmBLACK

STEERINGCOLUMN

6 mmORANGE

4 mmBLACK

4 m

mB

LAC

K


Unit No: SG1510H

Steering Gear Amended:080910


1 660764 1 Pilot valve AR70592 657424-1 1 Connector3 654947-7 4 Elbow4 654255 1 Exhaust filter5 657404 1 Valve - foot button6 654926 2 Adaptor7 657424-1 1 Connector8 657950-2 1 Reducer

655022 A/R Nylon pipe - 4mm Black

For details of Handbrake interlock see Page 4.19

PARTS MANUAL


ENVIRO 400

Front Axle - Dana - Swivel Assembly Amended:

Unit No: AF1511G,J&L

12

34

5

6

7

8

9

1011

1213

1415

16

17

1819

2021

2223

2425

2627

28

2930

31

40

32333435

36

3738

39

41

44

41

46

42

43

47

49,50

48,51

52

45

RH



Front Axle - Dana - Swivel Assembly Amended:260509


Use on & up to Chassis No 4363 inc 4369-4374, 4387-4398, 4402-4423659387 1 Front axle - complete - RHD - SB type calipers AF1511G

Used on & After Chassis No 4424 inc 4364-4368, 4375-4386, 4399-4401661335 1 Front axle - complete - RHD - SN type calipers AF1511J/AF1511L

1 607901-62 20 Brake bracket locknut2 658470-1 20 Brake bracket stud3 658470-2 1 Swivel4 658470-3 1 King pin oil seal (top)5 658470-4 1 King pin bush (top)6 657688-25 1 Top cap spacer7 658470-6 1 Top cap foam insert8 658095-20 1 Top cap9 658470-8 1 Top cap lubricator 10 658470-9 1 Top steering lever 11 658470-10 2 Top lever bolt 12a 658470-11 A/R Swivel bearing. setting shim - 0.13 mm 12b 658470-12 A/R Swivel bearing. setting shim - 0.25 mm 12c 658470-13 A/R Swivel bearing. setting shim - 0.50 mm 12d 658470-14 A/R Swivel bearing. setting shim - 0.20 mm 13 658470-15 2 King pin thrust bearing14 606624-134 2 Cotter pin nut 1/2" UNF15 659387-3 2 Cotter pin washer16 658470-16 1 Axle bed17 658470-17 2 Cotter pin 18 - - Not required on this application19 - - Not required on this application20 658470-52 2 ABS sensor kit (per axle)21 658923-24 1 Sensor bush (supplied as part of item 20)

PARTS MANUAL


ENVIRO 400



12

34

5

6

7

8

9

1011

1213

1415

16

17

1819

2021

2223

2425

2627

28

2930

31

40

32333435

36

3738

39

41

44

41

46

42

43

47

49,50

48,51

52

45

RH



Front Axle - Dana - Swivel Assembly Amended:130614


22a 659387-5 2 Lockstop screw L/H & R/H 22b 658521-12 2 Lockstop screw R/H

68256-61 1 Shim axle stop 68256-63 1 Shim axle stop68256-64 1 Shim axle stop

23 658470-20 3 Lockstop nut24 658470-21 2 Bottom lever bolt25 658470-22 2 Bottom lever bolt

26 659387-6 1 Bottom lever R/H658470-24 1 Bottom lever L/H658470-27 1 Tie rod assembly :

27 658521-16 2 Ball pin nut 28 658521-17 2 Split pin 29 659387-7 1 Tie rod 30 658521-20 2 Socket Clamp

658521-19 2 Socket clamp pinch bolt658521-21 2 Socket clamp pinch nut

31a 658521-22 1 Socket assembly R/H 31b 658521-23 1 Socket assembly L/H 32 658470-8 1 Bottom cap lubricator33 658095-20 1 Bottom cap34 658470-6 1 Bottom cap foam insert 35 657688-25 1 Bottom cap spacer 36 658470-28 1 King pin37 658470-4 1 King pin bush (bottom)38 658470-3 1 King pin oil seal (bottom)39 655387-5 1 Thrust washer (hub bearing)40 655387-4 2 Hub nut

PARTS MANUAL


ENVIRO 400



12

34

5

6

7

8

9

1011

1213

1415

16

17

1819

2021

2223

2425

2627

28

2930

31

40

32333435

36

3738

39

41

44

41

46

42

43

47

49,50

48,51

52

45

RH





41 438300 1 Plate - bracket support AL1543-142 MCS 3610 25 2 Cap screw43 431400 1 Bracket - brake pipe - upper

44a 432004 1 Bracket - brake hose - LH44b 432005 1 Bracket - brake hose - RH

45 655768-2 2 Swivel elbow - pipe to bracket46 MCN 510P 2 Nut - self locking

47a 438282 2 Brake pipe asssy - LH47b 438281 2 Brake pipe asssy - RH

48 MCS 3610 20 2 Cap screw49 MCB 108 16P 1 Bolt - bracket to backplate50 WMC 8SP 1 Washer - spring51 WMC 10SP 1 Washer - spring52 655768-4 1 Elbow - pipe to bulhead bracket

PARTS MANUAL


ENVIRO 400



4

5

6

7

8

912

13

1415

17

32333435

36

3738



Front Axle - Dana - Swivel kits Amended:110907


SWIVEL PIN SERVICE KIT

1 Comprising items: 4, 5,6, 8, 9, 12 to 15 17, 32 to 38 With cap/ lubricator658109-14 1 One hub set

PARTS MANUAL


ENVIRO 400

Front Axle - Dana - Hub and Brake assembly Amended:010708


12

3

4 5a6a

789

10

5b

SN

SB

658470,659387,661335



Front Axle - Dana - Hub and Brake assembly Amended:170209


1 650723-4 20 Wheel nut 2 658470-31 2 Hub flange 3 658470-32 20 Wheel stud (R/H Thread)4 - 1 Brake Caliper assembly L.H & R.H (See Braking System)

5a 655387-24 12 Brake Caliper retaining washer - SB Caliper6a 658470-35 12 Brake Caliper retaining Bolt - SB Caliper5b - - Not required on this application 6b 661336-1 12 Brake Caliper retaining Bolt - SN Caliper

7 658470-36 1 Brake Bracket R/H658470-37 1 Brake Bracket L/H

8 658470-38 2 Unitised Hub Bearing Alignment tool E6609 658470-39 2 Brake Disc

10 658521-33 28 Hub Flange Bolt

PARTS MANUAL


ENVIRO 400

Front Axle - ZF - Swivel assembly Amended:120609

Unit No: AF1513A

4

12

5

3

68

7

9

1011

121314

15

16

17

18

19

20

17

18

19

20

21/2223

2423

25 26

27 28

661773

29


Unit No: AF1513A

Front Axle - ZF - Swivel assembly Amended:180811


661773 1 Front axle - complete - RHD - SN type calipers

1 661773-1 2 Cover2 661773-2 2 ‘O’ ring3 661773-3 2 Hub4 661773-4 2 Hexagon screw5 661773-5 20 Screw - “torx”6 661773-6 20 Wheel bolt7 661773-7 4 Nut - slotted8 661773-8 2 Lock plate9 661773-9 2 Brake Disc10 661773-10 2 ‘O’ ring - shaft seal11 661773-11 2 Bearing Unit12 661773-12 2 ‘O’ ring 13 661773-13 2 Ring - bearing unit14 661773-14 2 ABS pulse ring15 661773-15 2 Swivel16 661773-16 2 Swivel pin17 661773-17 4 Sealing ring 18 661773-18 8 Bearing sleeve19 661773-19 4 Top cap assembly20 661773-20 4 Circlip21 661773-21 1 Steering lever - RH22 661773-22 1 Steering lever - LH23 661773-23 6 Bolt - steering levers24 661773-24 1 Steering lever - upper RH25 653877-8 2 ABS sensor26 653877-7 2 Bush - ABS sensor27 661773-28 2 Stop screw28 661773-29 2 Nut - stop screw29 651043-4 20 Wheel nut

PARTS MANUAL


ENVIRO 400

Front Axle - ZF - Axle Beam Amended:

Unit No: AF1513A

661773

4

17,8

2 35/6

9

13

12

1110


Unit No: AF1513A

Front Axle - ZF - Axle Beam Amended:


661773 1 Front axle - complete - RHD - SN type calipers

1 661773-25 1 Tie rod2 661773-31 1 Ball joint3 661773-32 1 Theaded sleeve4 661773-33 1 Clamp5 661773-34 1 Screw - clamp6 661773-35 1 Nut - clamp7 661773-36 1 Nut - castle8 661773-37 1 Split pin9 661773-30 1 Axle Beam10 661773-40 2 Bolt - fitted - caliper securing11 661773-41 10 Screw - caliper securing12 661773-38 1 Roller Bearing13 - A/R Shims available in thicknesses in from 3.00 mm in increments of 0.05mm

down to 2.2 mm.

BRAKE PIPES AND BRACKETS432004 1 Bracket - brake hose - LH 432005 1 Bracket - brake hose - RHMCS 108 20P 4 SetscrewWMC 8SP 4 Washer - spring446199 1 Pipe assembly - brake - LH446200 1 Pipe assembly - brake - RH446201 2 Bracket - pipe support - upper - “twisted”MCB 108 16P 2 BoltWMC 8SP 2 Washer - spring

PARTS MANUAL


A

Abbreviations, 1.24

Air Cleaner, 2.2

Air Conditioning, 2.84

Air Dryer, 4.24

Air Suspension, 6.2

Alternator Mounting, 2.80

B

Battery Carrier, 5.20

Battery Carrier & Rear Frame Area, 5.24, 5.38

Brake Actuators & Chambers, 4.18

Brake Caliper - SB, 4.28

Brake Caliper- SN, 4.32

Brake Caliper Spares - SB type, 4.30

Brake Caliper Spares - SN, 4.34

Brake Chambers, 4.18

Brake Tubing, 4.36

Braking, 4.1

Braking System - ABS/ASR, 4.2, 4.4, 4.10, 4.12

C

Cab Floor, 6.24

Cables, 5.14, 5.37

Cooling Pack Assembly, 2.16, 2.18

Cooling System - Voith, 2.4

Cooling System - ZF, 2.10, 2.12

D

Drive Axle - Differential Assembly, 3.12

Drive Axle - Axle Casing, 3.14

Drive Axle - Brake, 3.22

Drive Axle - Gantry, 3.18

Drive Axle - Gantry Drive, 3.16

Drive Axle - Input, 3.10

Drive Axle - Output, 3.20

Drive Shaft, 3.8

E

Electrical System, 5.1

Electrical System - Miscellaneous, 5.18

Engine, 2.1

Engine and Mounting - Voith, 2.68

Engine and Mounting - ZF, 2.72, 2.74

Engine Fuel Filter, 2.56

Engine Service Sundries, 2.78

Exhaust Gas Processor, 2.24, 2.26, 2.30

Exhaust Gas Processor System - Insulation, 2.28

F

Fastener Identification, 1.16, 1.21

Foot Controls, 6.24

Footbrake Valve, 4.20

Frame Assembly, 6.20, 6.22

Front - EDC, 5.6, 5.28

Front Air Suspension, 6.10, 6.12

Front Axle, 7.1

Front Axle - Dana - Swivel Assembly, 7.10

Front Axle - ZF - Swivel assembly, 7.20

Fuel System Pipework, 2.46, 2.48, 2.50, 2.52,2.54, 2.56

Fuel Tank Assembly, 2.36

Fuel Tank Assembly - Identic, 2.38

Fuel Tank Assembly - Posilock, 2.40

Fuel Tank Assembly - Wheelarch, 2.42

G

General, 1.1

H

Handbrake Interlock, 4.26

Harnesses, 5.36

Header Tank, 2.22

Health and Safety, 1.2

Hydraulic Fan Reservoir, 2.66

Hydraulic System, 2.58, 2.60, 2.62

I

Instrument Binnacle, 5.2, 5.4, 5.26

Instrumentation, 5.1

Intercooler Assembly, 2.20

Alphabetical Index Amended:

ENVIRO 400


L

Levelling Valve Linkage, 6.18

Lubricants and Fluids, 1.22

M

Main Index, 7

O

Oil Filler, 2.76

P

PCB - Front - EDC, 5.8, 5.30

PCB - Rear - EDC, 5.12, 5.34

Pipe Fittings - ABS/ASR, 4.6, 4.8, 4.14, 4.16

Q

Quick Reference Spares, 1.6, 1.14

R

Rear - EDC, 5.10, 5.32

Rear Suspension, 6.14

Regional PartsManagers, 4

Regional Service Managers, 5

S

Safety, 1.2

Saloon Heater Pipework, 2.82

Service Assistance, 3

Service Centres, 6

Spare Parts, 3

Steering, 7.1

Steering Column, 7.2, 7.4

Steering Column Spares, 7.6

Steering Gear, 7.8

Steering Reservoir, 2.64

Suspension, Frame, Wheels, 6.1

T

Transmission - ZF, 3.4, 3.6

Transmission- Voith, 3.2

Tyres, 6.26, 6.28

U

Urea Tank Assembly, 2.32

Urea Tank Assembly - Identic, 2.34

V

Vehicle Identification Number, 1.5

W

Wheels, 6.26, 6.28

Alphabetical Index Amended:

chassis parts manual

Documents